18643882-CO2FC88CDLSRMOIMID-Case 850d 855d Crawler Dozer Loader Service Repair Manual - Improved - Download

1
8500/8550 CRAWLERS
Table of Contents
DIVISION/SECTION SECTION NO. FORM NO.
1 GENERAL
Safety Rules, Service Manual Introduction, and Torque Specifications ........................... 1001 8-16530
Maintenance and Lubrication ............................................................................................ 1002 8-42190
General Engine Specifications ........................................................................................... 1010 8-26920
Detailed Engine Specifications .......................................................................................... 1024 8-26061
2 ENGINES
Engine and Radiator Removal and Installation ................................................................. 2000 8-42190
Engine Accessories (Air Cleaner, Ether Injection System,
Muffler, Turbocharger, and Torque Converter) .............................................................. 2001 8-42190
Engine Stall Tests .............................................................................................................. 2002 8-42190
Cylinder Head and Valve Train .......................................................................................... 2415 8-26071
Cylinder Block, Pistons, Rods, Camshaft, Main Bearings,
Oil Seals, Flywheel and Crankshaft ............................................................................... 2425 8-26081
Lubrication System ............................................................................................................. 2445 8-26091
Cooling System .................................................................................................................. 2455 8-26101
Turbocharger ...................................................................................................................... 2465 8-26110
Turbocharger Failure Analysis ........................................................................................... 2565 9-78235
3 FUEL SYSTEM
Fuel Lines, Fuel Tank, and Engine Controls ..................................................................... 3001 8-42190
Fuel System and Filters ..................................................................................................... 3410 8-26131
Bosch Fuel Injection Pump, Drive Gear, and Timing ........................................................ 3412 8-26141
Fuel Filters .......................................................................................................................... 3413 8-26150
4 ELECTRICAL
Removal and Installation of Electrical Components .......................................................... 4001 8-42190
Electrical System Specifications and Troubleshooting .................................. :.................. 4002 8-16540
Wiring Diagrams ................................................................................................................. 4003 8-42190
Gauges ............................................................................................................................... 4004 8-42190
Batteries ............................................................................................................................. 4005 8-42190
Starter and Starter Solenoid ............................................................................................... 4006 8-42190
Delco-Remy Alternator ....................................................................................................... 4007 8-16550
45 Amp Alternator A186124 ............................................................................................... 4008 8-16560
45 Amp Alternator A 187916............................................................................................... 4009 8-16570
5 TRACK
Inspection of Track System Components ......................................................................... 5501 8-16580
Case Lubricated Track ....................................................................................................... 5504 8-16590
Standard Track and Track Frame ...................................................................................... 5506 8-42191
Idler, Track Adjuster, and Recoil Housing ......................................................................... 5508 8-42190
Sprocket ............................................................................................................................. 5509 8-42190
Carrier Roller ...................................................................................................................... 5510 8-42190
Track Rollers ............................................................ ,......................................................... 5511 8-42190
IReprinted I
CASE CORPORATION Bur 8-16520 Printed in U.S.A.
Issued September 1990
2
DIVISION/SECTION SECTION NO. FORM NO.
6 POWER TRAIN
Transmission/Torque Converter Diagram and Troubleshooting ....................................... 6002 8-42190
Charging Pump .................................................................................................................. 6005 9-69230
Transmission Control Valve ............................................................................................... 6007 8-42190
Modulator Valve ................................................................................................................. 6008 8-42190
Removal and Installation of Torque Converter .................................................................. 6009 8-42190
Torque Converter ............................................................................................................... 6010 8-42190
Transmission .........-............................................................................................................. 6016 8-14630
Final Drive .......................................................................................................................... 6017 8-14640
Transmission Controls ....................................................................................................... 6018 9-69230
Drive Shaft .......................................................................................................................... 6021 9-69230
7 BRAKES
Brake Pedals, Removal and Installation of Master Cylinder, Adjustment and
Removing Air From Brake System ............................................................................. 7001 8-42190
Master Cylinder .................................................................................................................. 7002 8-42190
Brake .................................................................................................................................. 7003 8-42190
8 HYDRAULICS
Hydraulic Diagrams, Troubleshooting and Pressure Checks ........................................... 8002 8-16600
Cleaning the Hydraulic System .......................................................................................... 8003 8-42190
Rexroth Hydraulic Pump .................................................................................................... 8005 8-16620
Vickers Hydraulic Pump ..................................................................................................... 8006 8-16630
Equipment Control Valve ................................................................................................... 8007 8-16640
Cylinders ............................................................................................................................. 8090 8-42190
Backhoe Control Valve ....................................................................................................... 8107 8-41700
Removal and Installation of Stabilizer Control Valve ......................................................... 81 08 8-42190
Stabilizer Control Valve ...................................................................................................... 8109 8-42190
9 MOUNTED EQUIPMENT
Air Conditioning Troubleshooting ...................................................................................... 9002 8-42180
Air Conditioning System ..................................................................................................... 9003 8-42190
Loader ................................................................................................................................ 9010 8-42190
Blade on Dozer Models ..................................................................................................... 9020 8-42190
Ripper ................................................................................................................................. 9031 8-42190
ROPS Cab and Canopy ..................................................................................................... 9061 8-42190
Operators Seat and Seat Belt ............................................................................................ 9064 8-42190
Suspension Seat ................................................................................................................ 9065 8-42190
Backhoe ............................................................................................................................. 91 00 8-42190
Winch .................................................................................................................................. 9300 8-41960
CONTENTS OF POCKET
Wiring Diagram ............................................................................................................................................. 850481
Hydraulic Schematic for Dozer ..................................................................................................................... 850609
Hydraulic Schematic for Loader ................................................................................................................... 850610
Bur 8-16520 Issued 9-90 Printed in U.S.A

Section
1001
SAFETY RULES,
SERVICE MANUAL INTRODUCTION
AND
TORQUE SPECIFICATIONS
TABLE OF CONTENTS
Safety Rules ........................... 1001-2 Torque Specifications . . . . . . . . . . . . . . . . . . 1001-5
Service Manual Introduction . . . . . . . . . . . . 1001-4
Bur 8-16530 Printed in U.S.A.

CASE CORPORATION Issued September 1990
1001-2
SAFETY RULES
A This Symbol Shows Important Information About Safety In This Manual.

When You See This Symbol, Carefully Read The Information That
Follows and Understand The Possible Causes of Injury Or Death. 1-1-A
IMPORTANT: To prevent injury on job, fol- DANGER: Before you move the backhoe
low the Warning, Caution, and Danger notes in this h.boom to either side, make sure that all per-
section and other sections throughout this man- . . sons are out of the way. A swinging boom
ual. Follow the instructions carefully. can crush.
48-54
The procedures recommended and shown in
this manual are good, effective service methods.
However, all possible procedures and service haz-
ards may not be covered. Therefore, if you use a
A WARNING: Read operator's manual to
familiarize yourself with control/ever functions.
46-27
tool or procedure not recommended, you must
make sure that the method you select is a safe WARNING: Operate tractor and eqwp-
method. h. ment controls from the seat pos1t10n only
. . Any other method could result 1n senous
Put the warning tag shown below on the key for InJury.
the key switch when you are servicing or repairing 48-55
this machine. One warning tag is on every new
machine. You can buy additional warning tags,
part number331-4614, from Service Parts Supply.
h.WARNING: This is a one man machine,
. . no riders allowed. 35-8
WARNING: If you wear clothing that is

too loose or do not use the correct safety
equipment for your job, you can be injured.
h. Always wear clothing that will not catch on
. . objects. Extra safety equipment that can
be required includes hard hat. safety
shoes, ear protection. eye or face protec-
tion, heavy gloves and refiector clothing.
45-3-A
Reason - - - - - -
S1gned by - - - - -
780449
DANGER: Engine exhaust fumes can WARNING: When working in the area of
cause death. If it is necessary to start the L}..
the fan belt with the engine running, avoid
engine in a closed place. remove the ex- . . loose clothing if possible, and use extreme
h.haust fumes from the area with an exhaust caution. 35-4
. . pipe extension. If yo•J do not have an ex-
haust pipe extension, open the doors and
L},., WARNING: Operate controls from the
get outside air into the area.
. . operator's seat only. 35-7
48-56
1001-3
845081
1. Lift Cylinder Support Strut
WARNING: When doing checks and

/);. tests on the equipment hydraulics, fol-
.. low the procedures as they are written.
DO NOT change the procedure. 47-44 CAUTION: When servtcmg or repairing
the machine, keep the shop floor and opera-
WARNING: When putting the hydraulic tor's compartment and steps free of oil,
cylinders on this machine through the water, grease, tools, etc. Use an oil absorb-
necessary cycles to check operation or ing material and I or shop cloths as required.
to remove air from a circuit, make sure Use safe practices at all times. 4fJ-B
all people are out of the way. 47-45
CAUTION: Use su,table floor (serv1ce)
A WARNING: Use msulated gloves or

m1ttens when work1ng w1th hot parts.
47-41 A
h. jacks or cha1n ho1sts to ra1se wheels or
. . track off the floor Always block mach1ne 1n
place w1th swtable safety stands 40-7 -A
CAUTION: Some components of this

WARNING: 00 NOT. for any reason, /);. machine are very heavy. Use suitable lifting
weld the following parts. . . equipment or additional help as instructed in
this service manual. 4fJ-10
Swing tower
A Support for swing cylinders

Stabilizer leg
Cast stabilizer foot
Bucket links, loader or backhoe
Welding will cause failure of the part and

result in personal injury. 48-93
1001-4
SERVICE MANUAL INTRODUCTION

This service manual has been prepared with Page Numbers
the latest service information available. Troub-
leshooting, removal, disassembly, inspection and All page numbers are made of two numbers
installation procedures, and complete specifica- separated by a dash, such as 4002-9. The number
tions and tightening references can be found in before the dash is the section number. The number
most sections. Some sections have drawings but following the dash is the page number in that sec-
no written procedure because the job is so easily tion. Page numbers will be found at the upper right
done. This service manual is one of the most im- or left of each page.
portant tools available to the service technician.
Illustrations
Right, Left, Front, and Rear
Illustrations are put as near as possible to the
The terms right-hand and left-hand and front text and are to be used as part of the text.
and rear as used in this manual indicate the right
and left sides, and front and rear of the machine as Clear and Simple English
seen from the operator's seat for correct operation
of the machine or attachment. This manual is written in C.A.S.E. (Clear and
Simple English). C.A.S.E. is easier to read and un-
derstand than "regular" English because C.A.S.E.
uses a small number of common words and has
special rules for writing.
1
Special Tools
2
Special tools are needed to remove and install, dis-
assemble and assemble, check and adjust some com-
ponent parts of this machine. Some special tools can
~
be easily made locally and the necessary information to
make the tool is in this service manual. Other special
tools are more difficult to make locally and are available
from Service Tools in the U.S. and from VL Churchill Ltd.
in Europe. Use these tools according to the instructions
811552
1. Right Side-Backhoe 5. Front-Backhoe in this service manual for your personal safety and to do
2. Left Side-Backhoe 6. Rear-Backhoe the job correctly.
3. Left Side-Machine 7. Rear-Machine
4. Right Side-Machine B. Front-Machine In the U.S. and Canada, order the tools from
Service Tools
Text P.O. Box 314
Owatonna, MN
If the service manual is for more than one ma- 55060
chine or different models of components (plane-
tary axles, gear boxes, control valves, etc.) the In Europe order the tools from
procedures have the steps necessary to service
each model. VL Churchill Ltd.
P.O. Box 3, Daventry
Table of Contents Northants NN11 4NF
England
A Table of Contents is in the front of this man-
ual. The Table of Contents shows the main divi-
sions and the sections that are in each division. The
individual sections, where necessary, have a Table
of Contents on the second page of that section.
1001-5
TORQUE SPECIFICATIONS - U.S. HARDWARE

Use the torques in this chart when special tor- Grade 8 Bolts, Nuts, and Studs
0 ® @
ques are not given. These torques apply to fasten-
ers with both UNC and UNF threads as received \
from suppliers, dry, or when lubricated with engine
Pound- Newton Kilogram
oil. Not applicable if special graphites, moly-disul-
Size Feet metres metres
fide greases, or other extreme pressure lubricants
are used. 1/4 in 12-15 16-20 1.7-2.1
6.4 mm
Grade 5 Bolts, Nuts, and Studs 5/16 in 24-29 33-39 3.3-4.0
7.9mm
0 0 @
3/8 in
9.5mm
45-54 61-73 6.2-7.5
Size Feet metres metres 7/16 in 70-84 95-114 9.7-11.6

11.1 mm
1/4 in 9-11 12-15 1.2-1.5 1/2 in 110-132 149-179 15.2-18.2
6.4 mm 12.7 mm
9/16 in 160-192 217-260 22.1-26.5
5/16 in 17-21 23-28 2.4-2.9
14.3 mm
7.9mm
5/8 in 220-264 298-358 30.4-36.5
3/8 in 35-42 48-57 4.8-5.8 15.9 mm
9.5mm 3/4 in 380-456 515-618 52.5-63.0
..
19.0 mm
7/16 in 54-64 73-87 7.5-8.8
7/8 in 600-720 814-976 83.0-99.5
11.1 mm
22.2 mm
1/2 in 80-96 109-130 11.1-13.3 1.0 in 900-1080 1220-1465 124-149
12.7 mm 25.4 mm
1-1/8 in 1280-1440 1736-1953 177-199
9/16 in 110-132 149-179 15.2-18.2 28.6 mm
14.3 mm
1-1/4 in 1820-2000 2468-2712 252-277
31.8 mm
5/8 in 150-180 203-244 20.8-24.9
15.9 mm 1-3/8 in 2380-2720 3227-3688 329-376
34.9 mm
3/4 in 270-324 366-439 37.3-44.8 1-1/2 in 3160-3560 4285-4827 437-492
19.0 mm 38.1 mm
7/8 in 400-480 542-651 55.3-66.4

22.2 mm
1.0 in 580-696 787-944 80.2-96.2

25.4 mm
1-1/8 in 800-880 1085-1193 111-122

28.6 mm
1-1/4 in 1120-1240 1519-1681 155-171

31.8 mm
1-3/8 in 1460-1680 1980-2278 202-232

34.9 mm
1-1/2 in 1940-2200 2631-2983 268-304

38.1 mm
811360A
1001-6
TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS

Tube OD Thread Pound- Newton Kilogram Tube OD Thread Pound- Newton Kilogram
Hose ID Size Feet metres metres Hose ID Size Feet metres metres
37 Degree Flare Fittings Straight Threads with 0-ring

1/4 in 7/16-20 6-12 8-16 0.8-1.7 1/4 in 7/16-20 12-19 16-25 1.7-2.6
6.4 mm 6.4 mm
5/16 in 1/2-20 8-16 11-21 1.1-2.2 5/16 in 1/2-20 16-25 22-33 2.2-3.5
7.9 mm 7.9 mm
3/8 in 9/16-18 10-25 14-33 1.4-3.5 3/8 in 9/16-18 25-40 34-54 3.5-5.5
9.5 mm 9.5 mm
1/2 in 3/4-16 15-42 20-56 2.1-5.8 1/2 in 3/4-16 42-67 57-90 5.8-9.3
12.7 mm 12.7 mm
5/8 in 7/8-14 25-58 34-78 3.5-8.0 5/8 in 7/8-14 58-92 79-124 8.0-12.7
15.9 mm 15.9 mm
3/4 in 1-1/16-12 40-80 54-108 5.5-11.1 3/4 in 1-1/16-12 80-128 108-174 11.1-17.8
19.0 mm 19.0 mm
7/8 in 1-3/16-12 60-100 81-135 8.3-13.9 718 in 1-3/16-12 100-160 136-216 13.8-22.1
22.2 mm 22.2 mm
1.0 in 1-5/16-12 75-117 102-158 10.4-16.2 1.0 in 1-5/16-12 117-187 159-253 16.2-25.9
25.4 mm 25.4 mm
1-1/4 in 1-5/8-12 l25-165 169-223 17.3-22.8 1-1/4 in 1-5/8-12 165-264 224-357 22.8-36.5
31.8 mm 31.8 mm
1-1/2 in 1-7/8-12 210-250 285-'338 29.0-34.6 1-1/2 in 1-7/8-12 250-400 339-542 34.6-55.3
38.1 mm 38.1 mm
Split Flange Mounting Bolts

Size Feet metres metres
5/16-18 15-20 20-27 2.1-2.8
3/8-16 20-25 26-33 2.8-3.5
7/16-14 34-45 47-61 4.7-6.2
1/2-13 55-65 74-88 7.6-9.0
5/8-11 140-150 190-203 19.4-20.7

811361A
1002
FLUIDS AND LUBRICANTS CHART
AND MAINTENANCE CHART
TABLE OF CONTENTS
Fluid and Lubricants Chart .................................................................... 1002-2
Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002-3
Written In Clear
And
Simple
English
8-42190 Printed in U.S.A.

CASE CORPORATION
1002-2
FLUIDS AND LUBRICANTS CHART

COMPONENT CAPACITY SPECIFICATION
u.s. METRIC
Fuel tank 38 gallons 144 litres See Operators Manual
Crankcase 16 quarts 15.2 litres Multi-viscosity engine oil is specified

for both engines. Single viscosity
engine oil can be used if a multi-
viscosity oil is not available.
API classification:
Without turbocharger CC or CC/CD
With turbocharger CC/CD or CD
Multi-viscosity engine oil
Above 30° F (-1 o C) ....... SAE 20W-40
Above 10° F (-12°C) ...... SAE 15W-40
Above 90° F (32° C) ...... SAE 10W-30
Single viscosity engine oil
Above 50° F (1oo C) ........... SAE40
Above 40° F (5° C) ............ SAE30
25 to 70° F (4 to 21 o C) .... SAE 20W-20
Reservoir for hydr~ulic 12 gallons 45 litres Case TCH Fluid

oil Alternate oil:
Type C3 hydraulic oil
Transmission 8.5 gallons 32 litres Case TCH Fluid

Alternate oil
Final drive (each) 7.5 quarts 7.1 litres Case FDL

Alternate gear lubricant
SAE 85/140 EP (API-GL-5)
Cooling system 5 gallons 19 litres A mixture of half ethylene glycol (anti-

freeze) and half water must be used at
all times. If the coldest outside temper-
atu re will be less -34 o F (-36° C),
add antifreeze.
Winch 9.5 quarts 9 litres Multipurpose gear. lubricant, API-GL-4

Above 0° F (-18° C) .............. SAE 90
Below 0° F (-18°C) .............. SAE 75
Batteries As required Add drinking water or distilled water.
Master cylinders As required Case TCH Fluid

Alternate oil
Winch control As required DOT 3 brake fluid
Grease fittings As required Molydisulfide multipurpose grease

1002-3
MAINTENANCE CHART
This chart shows the maximum intervals of service for the correct maintenance of the machine. Shorten
the intervals as required when operating conditions are severe.
INTERVAL SERVICE INSTRUCTIONS
After the first 20 Tighten the tension rods for the backhoe, Section 9100
hours of operation for if equipped. Tighten again after every 50
new machine hours until the turnbuckles stay tight.
Do the After Delivery Check Operators Manual
After first 10, 20, 50 If equipped with a backhoe, tighten the Section 9100
100 and 200 hours of nut on the bottom pivot pin for the swing
operation tower to the specified torque.
After the first 100 Tighten all clamps on hoses at connecting

hours of operation points (radiator, suction line, etc.
After 10 hours of Check level of engine oil Operators Manual

operation or daily,
whichever occurs first Check level of transmission oil. Section 6002
Check level of hydraulic oil. Operators Manual

-
Clean or replace decals that cannot be read. Operators Manual
After 50 hours of Check dust valve and wing nut for cover for Operators Manual
operation air cleaner.
Check level of coolant in coolant reservoir. Operators Manual
Drain water from primary fuel filter. Operators Manual
Lubricate pivot points for loader and blade. Operators Manual
After 100 hours of Check adjustment of parking brake. Section 7001

operation
Clean spark arresting muffler. Section 2001
Check level of oil in winch and adapter. Seeton 9300
Check level of fluid in winch control. Section 9300
Lubricate universal joints and slip spline Operators Manual

(severe conditions).
1002-4
After 250 hours of Check level of OIL in master cylinders. Operators Manual
operation
Change engine oil and replace oil filter. Operators Manual
Check level of gear lubricant in final Operators Manual

drives.
Check tension of drive belt for air Section 9003

conditioner compressor.
Check the level of the fluid in the Section 4005

batteries.
Check coolant level in radiator. Operators Manual
Lubricate pivot points for brake pedals. Operators Manual
Lubricate pivot points for loader and Operators Manual

blade control levers and backhoe control
levers.
Lubricate suspension seat. Section 9065
After 500 hours of

- Replace fuel filters. Section 3410
operation
Replace filter in hydraulic reservoir. Section 8002
Replace transmission filter. Section 6002
Lubricate universal joints and slip point Operators Manual

(normal conditions).
Inspect ROPS canopy or cab. Section 9061
After 1000 hours of Change the oil in the transmission. Section 6002
operatio_n
Change oil in hydraulic reservoir. Section 8002
Clean breather for hydraulic reservoir. Section 8002
Change gear lubricant in final drives. Operators Manual
Check engine valve clearance. Section 2415
Clean breather and relief valve in filler Operators Manual

for fuel tank.
Change oil in winch and adapter. Section 9300
Clean batteries, battery carrier, and Section 4005

terminals on battery cables.
Clean filter for ROPS cab. Section 9061

1002-5
After 2000 hours of Drain, flush and fill cooling system. Operators Manual
operation
As required Check tension of track(s). Section 5506
Tighten bolts for track shoes to the Section 5506

specified torque.
Adjust the brakes. Section 7001
Adjust the parking brake. Section 7001
Service the air cleaner. Section 2001
Clean precleaner for air cleaner, if Section 2001

equipped.
If equipped with a winch, adjust the Section 9300

brake for the winch.
Section
1010
GENERAL ENGINE SPECIFICATIONS
Written In Clear
And
Simple
English
IMPORTANT: This engine was made using the metric measurement system.
All measurements and checks must be made with metric tools to make sure of
an accurate reading when inspecting parts.
Rae 8-26920 Printed in U.S.A.

CASE CORPORATION March, 1985
1010-2
ENGINE SPECIFICATIONS
General
Type ....................................................... 6 Cylinder, 4 Stroke Cycle, Valve-In-Head
Firing Order .............................................................................. 1,5,3,6,2,4
Bore ....................................................................................... 102 mm
Stroke ...................................................................................... 120 mm
Piston Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.88 Litres
Compression Ratio ......................................................................... 17.0 to 1
No Load Governed Speed .......................................................... 2130 to 2220 RPM
Rated Engine Speed ............................................................... 2095 to 2175 RPM
Engine Idle Speed ................................................................... 700 to 750 RPM
Valve Tappet Clearance (Exhaust) (Cold) .................................................... 0.508 mm
(lntake)(Cold) ..................................................... 0.254 mm
Thermostat Operating Range .......................................... 181 oF to 203° F (83° C to 95° C)
Piston and Connecting Rods

Rings Per Piston ................................................................................... 3
Number of Compression Rings ..................................................................... 2
Number of Oil Rings (two piece) ................................................................... 1
Type of Pins .............................................................................. Full Float
Type Bearings ............................................................ Steel Back Leaded Bronze
Main Bearings
Number of Bearings ............................................................................... 7
Type of Bearings ....................................................................... Replaceable
Engine Lubricating System

Oil Pressure ............................................ 42 to 54 PSI (290 to 372 kPa)(2.90 to 3.72 bar)
with Engine Warm at Rated Engine Speed
Type of System ...................................................... Pressure and Spray Lubrication
Oil Pump ................................................................................ Rotor Type
Oil Filter ..................................................................... Full Flow Turn-on Type
Oil Capacity (with filter) .......................................................... 16 Quarts (15 litres)
(without filter) ..................................................... 15 Quarts (14.3 litres)
Fuel System
Fuel Injection Pump ............................................................................ CAV
Pump Timing ............................................................................ Top Center
Fuel Injectors ................................................. Bosch 17 mm Opening Pressure (New)
3190 to 3310 PSI (21 994 to 22 822 kPa)(220 to 228 Bar)
Governor ................................................ Variable Speed, a Part of the Injection Pump
First Stage Fuel Filter .................................................................. Turn on Type
Second Stage Fuel Filter ............................................................... Turn on Type
Lift Pump ................................................... 5 to 7 PSI (34 to 48 kPa)(0.34 to 0.48 Bar)
NOTE: The cAsE coRPORATION reserves the right to make improvements in

design or changes in specifications at any time without incurring any obliga-
tion to install them on units previously sold.
Rae 8-26920 Issued 3-85 Printed in U.S.A.

Section
1024
SPECIFICATION DETAILS
Written In Clear
And
SimP..Ie
English
Rae 8-26061 Printed in U.S.A

CASE CORI?()RATION October, 1984 (Revised March, 1985)
1024-2
TABLE OF CONTENTS
RUN-IN INSTRUCTIONS .......................................................................... 3
ENGINE SPECIFICATION DETAILS

Cylinder Block .................................................................................. 4
Service Cylinder Sleeve .......................................................................... 4
Piston .......................................................................................... 4
Piston Pin ...................................................................................... 4
Piston Rings ...............................................~ ..................................... 5
Cylinder Head .................................................................................. 5
Tappets ........................................................................................ 5
Connecting Rod ................................................................................. 5
Crankshaft ...................................................................................... 6
Camshaft ....................................................................................... 7
Valve Push Rod Lifters ........................................................................... 7
Gear Train ...................................................................................... 7
Rocker Arm Assembly ........................................................................... 7
Turbocharger .......................................................... ~ ........................ 7
Intake Valve ..................................................................................... 8
Exhaust Valve ................................................................................... 8
Valve Springs ................................................................................... 8
SPECIAL TORQUES ...............•........................................................... 9-11
Rae 8-26061 Revised 3-85 Printed in U.S.A.

1024-3
RUN-IN INSTRUCTIONS
Engine Lubrication
Fill the 6-590 engine crankcase with CC or CD service classification oil that has the correct viscosity rating for
the ambient air temperature. Install new oil filters, after the engine has been rebuilt.
Fill the 6T-590 and the 6TA-590 engine crankcase with CD service classification oil that has the correct
viscosity rating for the ambient air temperature. Install new oil filters, after the engine has been rebuilt.
Run-In Procedure For Rebuilt Engine

Step 1 Disconnect the wire to the electric shut-off on the injection pump so that the engine will not start.
Crank the engine for 30 seconds until there is oil pressure, then reconnect the wire.
Step 2 Remove the air from the cooling system at the temperature sending unit for the 6-590 and 6T-590
engine. Loosen the upper plug on the aftercooler to remove the air from the cooling system for the
6TA-590 engine.
Step 3 Run the engine at 1000 RPM minimum load for 5 minutes and check for oil leaks.
Step 4 During the Run-In, continue to check the oil pressure, coolant level, and coolant temperature.
Run-In Procedure For Rebuilt Engines (With A Dynamometer)

The following procedure must be followed when using a PTO dynamometer to Run-In the engine. The
dynamometer will control the engine load at each speed and will remove stress on new parts during Run-ln.
During the Run-In, continue to check the oil pressure, coolant level and coolant temperature.
STEP TIME ENGINE SPEED DYNAMOMETER SCALE LOAD

1 5 Minutes 1000 RPM 50
2 5 Minutes 1100 RPM 1/2
3 5 Minutes 2200 RPM Full
Run-In Procedure for Rebuilt Engines (Without A Dynamometer)

STEP TIME ENGINE SPEED LOAD
1 5 Minutes 1000 RPM No Load
2 5 Minutes 1100RPM Light Load
3 5 Minutes 2200 RPM Full
Run-In Procedure (Agriculture Tractors)

For the first 8 hours of field operation stay one gear lower than normal. For the next 12 hours DO NOT "lug"
the engine. Prevent "lugging" by moving the lever to a lower gear. The engine must not be "lugged" below the
rated engine RPM during early hours of life.
Run-In Procedure (Construction Equipment)

For the first 8 hours, operate the engine at full throttle maintaining a normal load. DO NOT "baby" the engine,
but avoid converter or hydraulic stall. The engine must not be "lugged" below the Rated Engine RPM (Do not
stall the engine more than 10 seconds).

1024-4
ENGINE SPECIFICATION DETAILS

Cylinder Block Metric Value
Type ................................................................................... Non-Sleeved
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cast I ron
ID of Cylinder ................................................................... 102.00 to 102.04 mm
Maximum Service Limit ................................................................ 102.116 mm
Cylinder Out of Round (Maximum) ......................................................... 0.038 mm
Cylinder Taper (Maximum) ................................................................ 0.076 mm
0.5 mm Oversize Piston
Machine Cylinder Bore to ...................................................... 102.40 to 102.44 mm
Hone Cylinder Bore to ......................................................... 102.50 to 102.54 mm
Machine Cylinder Bore to ................................................... 102.900 to 102.960 mm
Hone Cylinder Bore to ......................................................... 103.00 to 103.04 mm
Service Cylinder Sleeve

Type ......................................................................... Dry, Can Be Replaced
Material ................................................................................... Cast Iron
Machine Cylinder Block Bore to ............................................... 104.485 to 104.515 mm
Installation ................................................................................ Press Fit
Hone Cylinder Bore to ........................................................... 102.00 to 102.10 mm
Piston
Type .................................................................................. Cam Ground
Material .............•............................................................... Aluminum alloy
OD at 12 mm From the Bottom, 90 Degrees From Piston Pin
Standard Size Piston ........................................................ 101.873 to 101.887 mm
Minimum Service Limit .............................................................. 101.823 mm
0.5 mm Oversize Piston ................................................. : ... 102.373 to 102.387 mm
1.0 mm Oversize Piston ..................................................... 102.873 to 102.887 mm
ID of Piston Pin Bore ............................................................ 40.006 to 40.012 mm
Maximum Service Limit ................................................................. 40.025 mm
Width of 1st Ring Groove (Top) .................................................... 2.465 to 2.485 mm
Width of 2nd Ring Groove (Intermediate) ........................................... 2.425 to 2.445 mm
Width of 3rd Ring Groove (Oil Ring) ................................................ 4.040 to 4.060 mm
Protrusion Above Cylinder Block (Maximum) ............................................... 0.660 mm
Piston Pin
Type ...................................................................................... Full Float
OD of Pin ....................................................................... 39.997 to 40.003 mm
Minimum Service Limit ................................................................. 39.990 mm

1024-5
Piston Rings
No. 1 Compression (6T-590 and 6TA-590 Engine) ........................ Key Stone Type (Barrel Face)
End Gap in 102.02 ID .............................................................. 0.40 to 0.70 mm
No. 1 Compression 6-590 Engine ...................................... Rectangular Type (Barrel Face)
End Gap in 102.02 ID .............................................................. 0.25 to 0.55 mm
Side Clearance .................................................................. 0.075 to 0.120 mm
No. 2 Compression ................................................... Rectangular Type (Taper Face)
End Gap in 102.02 ID .............................................................. 0.25 to 0.55 mm
No. 3 Oil Control Rings ................................................................... Two Piece
End Gap in 102.02 ID .............................................................. 0.25 to 0.55 mm
Side Clearance .......................................................................... 0.130 mm
Cylinder Head
Warpage (Maximum) ....................................................................... 0.20 mm
Lifters
Material .............................................................................. Hardened Iron
OD of Lifter ................................................................... 15.961 to 15.977 mm
Minimum Service Limit ............................................................... 15.960 mm
Bore Diameter in Block ........................................................ 16.000 to 16.030 mm
Maximum Service Limit ............................................................... 16.055 mm
Connecting Rod
Bushing ................................................................ Steel Backed Leaded Bronze
Bushing ID Installed (Ream to Size) .............................................. 40.053 to 40.067 mm
Bearing Liners .......................................................................... Replaceable
Journal ID Without Bearing Liners ............................................... 72.987 to 73.013 mm
Bearing Oil Clearance ............................................................. 0.038 to 0.116 mm
Maximum Service Limit .................................................................. 0.129 mm
Side Clearance .................................................................... 0.100 to 0.300 mm
Connecting Rod Bend (Maximum)
Without Bushing ........................................................................ 0.200 mm
With !;3ushing ........................................................................... 0.150 mm
Connecting Rod Twist (Maximum)
Without Bushing ........................................................................ 0.500 mm
With Bushing ........................................................................... 0.300 mm

1024-6
Crankshaft
Type ...................................................................... Hardened Steel, Balanced
Main Bearing Liners .................................................................... Replaceable __ ;
Crankshaft End Clearance ......................................................... 0.137 to 0.264 mm
Center Main Bearing Thrust Surface Thickness ............................................... 2.50 mm
Connecting Rod Journal
00, Standard ................................................................. 68.987 to 69.013 mm
Maximum Service Limit .........•..................................................... 68.962 mm
0.25 mm 00 Undersize, Grind to ............................................... 68.737 to 68.763 mm
Connecting Rod Journal Maximum Taper ................................................... 0.013 mm
Journals Out of Round Maximum ........................................................... 0.050 mm
Undersize Main Bearing Liners For Service ................................ 0.25, 0.50, 0.75 and 1.00 mm
Main Bearing Oil Clearance ........................................................ 0.041 to 0.119 mm
Main Bearing Journal
00, Standard ................................................................. 82.987 to 83.013 mm
Maximum Service Limit ....•.......................................................... 82.962 mm
Maximum Service Limit .....................•......................................... 82.712 mm
Maximum Service Limit ...•............•............................... ·............... 82.462 mm
0.75 mm 00 Undersize, Grind to ..............................................• 82.237 to 82.263 mm
Maximum Service Limit ............................•.................................. 81.962 mm
Main Bearing Journal Bore 10 No Liners .......................................... 87.982 to 88.018 mm
Main Journal Width:
1st, 2nd, 3rd, 5th and 6th ...................................................... 37.424 to 37.576 mm
4th ........................................................................... 37.475 to 37.525 mm
Connecting Rod Journals Width ................................................. 38.950 to 39.050 mm

1024-7
Camshaft
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hardened I ron
Bushing (Front Only) ................................................................. 1, Replaceable
Bushing Lubrication:
Front Bushing ................................................................. Pressure Lubricated
Intermediate .................................................................. Pressure Lubricated
Rear .......................................................................... Pressure Lubricated
Oil Clearance ..................................................................... 0.076 to 0.152 mm
10 of No.1 Bushing (Installed) ................................................... 54.107 to 54.133 mm
10 of No. 1 Oversize (57.36 to 57.40 mm 00) Service Bushing ...................... 54.107 to 54.133 mm
10 of No.2, 3, 4, 5 and 6 Service Bushing ......................................... 54.107 to 54.133 mm
Width of No. 1 Bushing ............................................................ 25.15 to 25.65 mm
Width of No.2, 3, 4, 5 and 6 Service Bushing ........................................ 17.75 to 18.25 mm
Camshaft Bushing Journal OD ................................................... 53.987 to 54.013 mm
Minimum Serviceable Limit •............................................................ 53.962 mm
Camshaft Bore Diameter in Block
No.1 Bushing ................................................................ 57.222 to 57.258 mm
No. 1 Oversize Bushing, Machine to ...............•............................ 57.722 to 57.758 mm
No.2, 3, 4, 5 and 6 Less Bushings .............................................. 54.107 to 54.133 mm
No. 2, 3, 4, 5 and 6 Oversize for Bushings, Machine to ........................... 57.222 to 57.258 mm
Camshaft Thrust Thickness .......................................•.................. 9.42 to 9.58 mm
Minimum Service Limit ................................................................... 9.34 mm
Camshaft Thrust Clearance ........................................................ 0.130 to 0.340 mm
Turbocharger
Horizontal Travel of Turbine Shaft .................•.................................. 0.10 to 0.16 mm
Gear Train
Backlash:
Crankshaft Gear to Camshaft Gear ............•.................................... 0.08 to 0.33 mm
Crankshaft Gear to Idler Gear ...................................................... 0.08 to 0.33 mm
Camshaft to Fuel Pump Gear ..........................•..............•..........•.. 0.08 to 0.33 mm
Idler Gear to Oil Pump ............................................................. 0.08 to 0.33 mm
Camshaft to Auxiliary ....•.......................•............................•.... 0.08 to 0.33 mm
Maximum Service Limit (All Gears) ...................................................... 0.45 mm
Rocker Arm Assembly

OD of Shaft ..................................................................... 18.963 to 18.975 mm
10 of Arm Bore .................................................................. 19.000 to 19.026 mm
Lubrication ................................................................ Pressure From Oil Gallery

1024-8
Intake Valve
Tappet Clearance (Cold) ................................................................... 0.254 mm
Face Angle .............................................................................. 29 Degrees
Face Run-Out ............................................................................. 0.038 mm
Valve Head Edge Thickness, Minimum ....................................................... 1.50 mm
Length ......................................................................... 128.84 to 129.46 mm
OD of Stem ....................................................................... 7.960 to 7.980 mm
Minimum Service Limit .................................................................. 7.940 mm
OD of Head ..................................................................... 44.870 to 45.130 mm
Seat Angle .............................................................................. 30 Degrees
Seat Contact Width .................................................................. 1.32 to 1.92 mm
Seat Run-Out .............................................................................. 0.10 mm
Insert Height ........................................................................ 6.84 to 6.96 mm
OD of Insert .................................................................... 47.063 to 47.089 mm
ID of Insert ................................................................................. Tapered
Valve Recession Below Head Surface ................................................. 0.99 to 1.52 mm
Maximum Service Limit ................................................................... 1.52 mm
ID of Valve Guide Bore ............................................................ 8.019 to 8.039 mm
Exhaust Valve
Tappet Clearance (Cold) ................................................................... 0.508 mm
Face Angle .............................................................................. 44 Degrees
Face Run-Out ............................................................................. 0.038 mm
Valve Head Edge Thickness, Minimum ....................................................... 1.50 mm
OD of Head ..................................................................... 41.870 to 42.130 mm
OD of Stem .......... .' ...................................................•........ 7.960 to 7.980 mm
Minimum Service Limit .................................................................. 7.940 mm
Length ......................................................................... 128.74 to 129.36 mm
Insert Seat Angle ........................................................................ 45 Degrees
Seat Contact Width .................................................................. 1.47 to 2.07 mm
Seat Run-Out .............................................................................. 0.10 mm
Insert Height ........................................................................ 6.65 to 6.77 mm
OD of Insert .................................................................... 43.713 to 43.739 mm
ID of Insert ................................................................................. Tapered
Valve Recession Below Head Surface ................................................. 0.99 to 1.52 mm
Maximum Service Limit ................................................................... 1.52 mm
ID of Valve Guide Bore ............................................................ 8.019 to 8.039 mm
Valve Springs
Free Length ............................................................................... 55.63 mm
Total Coils ..................................................................................... 7.25
Wire Diameter ..................................................................... 4.830 to 4.930 mm
Compressed to 38.53 mm .................................................. fValve Open) 785 to 839 N
Maximum Service Limit ...................................................................... 765 N
Compressed to 49.25 mm ................................................. (Valve Closed) 285 to 321 N
Minimum Service Limit ...................................................................... 270 N

1024-9
SPECIAL TORQUES
U.S. Value Metric Value
Aftercooler Bolts ................................................ 18 lb ft 24 Nm
(2.4 kgm)
Air Crossover Elbow to Intake Aftercooler ........................ 18 lb ft 24Nm
(2.4 kgm)
Alternator Bracket Bolts (Lower) ................................. 18 lb ft 24 Nm
(2.4 kgm)
Alternator Bracket Bolts (Upper) .................... , ............ 18 lb ft 24 Nm
(2.4 kgm)
Alternator Retaining Bolt ........................................ 18 lb ft 24 Nm
(2.4 kgm)
Belt Tensioner Bracket Bolts ..................................... 18 lb ft 24 Nm
(2.4 kgm)
Belt Tensioner Retaining Bolt .................................... 32 lb ft 43 Nm
(4.3 kgm)
Camshaft Retaining Bolts ........................................ 18 lb ft 24 Nm
(2.4 kgm)
Connecting Rod Bolts ........................................... 74 lb ft 100 Nm
(Lubricate Threads With Engine Oil) (10.0 kgm)
Exhaust Manifold Bolts .......................................... 32 lb ft 43 Nm
(4.3 kgm)
Fan Pulley Bracket Bolts ......................................... 18 lb ft 24 Nm
(2.4 kgm)
Fan Pulley Bolts (Grade 8.8) ..................................... 181b ft 24 Nm
(2.4 kgm)
Fan Pulley Bolts (Grade 10.9) .................................... 25 lb ft 34 Nm
(3.4 kgm)
Flywheel Housing Bolts .......................................... 45 lb ft 60Nm
(6.0 kgm)
Flywheel Retaining Bolts ....................................... 101 lb ft 137 Nm
(13.7 kgm)
Flywheel Housing Cover Bolts ................................... 181b ft 24 Nm
(2.4 kgm)
Fuel Filter Inlet Bolt ............................................. 24 lb ft 32 Nm
(3.2 kgm)
Fuel Air Removal Bolt ............................................ 41b ft 6Nm
(0.6 kgm)
Fuel Filter Inlet Nut .............................................. 24 lb ft 32Nm
(3.2 kgm)
Fuel Line Fitting (High Pressure) ................................. 18 lb ft 24Nm
(2.4 kgm)
Fuel Line Fitting (Low Pressure) .................................. 18 lb ft 24Nm
(2.4 kgm)
Fuel Pump Plug with Bronze Washer ............................. 17 lb ft 23Nm
(2.3 kgm)
Front Cover Bolts ............................................... 18 lb ft 24Nm
(2.4 kgm)
Front Housing Bolts ............................................. 18 lb ft 24Nm
(2.4 kgm)
1024-10
SPECIAL TORQUES {CONT'D)

Crankshaft Dampener Pulley .................................... 101 lb ft 137 Nm

(13.7 kgm)
Cylinder Head Bolts ............................................. 93 lb ft 126 Nm
(12.6 kgm)
Injection Pump Drive Gear Nut ................................... 48 lb ft 65 Nm
(6.5 kgm)
Injection Pump Lock Bolt ........................................ 22 lb ft 30 Nm
(3.0 kgm)
Injection Pump Retaining Nuts ................................... 18 lb ft 24 Nm
(2.4 kgm)
Injection Pump Bracket Bolts .................................... 18 lb ft 24 Nm
(2.4 kgm)
Injector Leak off Bolt ............................................ 11 lb ft 15 Nm
(1.5 kgm)
Injector Retaining Nut ........................................... 44 lb ft 60 Nm
(6.0 kgm)
Intake Manifold Bolts ............................................ 18 lb ft 24 Nm
(2.4 kgm)
Intake Manifold Plug ............................................ 92 lb ft 125 Nm
(12.5 kgm)
Engine Lift Bracket Bolts (Rear) .................................. 57 lb ft 77 Nm
(7.7 kgm)
Main Bearing Bolts .............................................. 129 lb ft 175 Nm
(Lubricate The Threads With Engine Oil) (17.5 kgm)
Oil Fill Tube Bolts ............................................... 32 lb ft 43Nm
(4.3 kgm)
Oil Pan Drain Plug .............................................. 55 lb ft 75 Nm
(7.5 kgm)
Oil Pan Heater Plug ............................................. 90 lb ft 122 Nm
(12.2 kgm)
Oil Pan Retaining Bolts .......................................... 18 lb ft 24 Nm
(2.4 kgm)
Oil Pump Retaining Bolts ........................................ 18 lb ft 24 Nm
(2.4 kgm)
Oil Inlet Tube Bolts .............................................. 18 lb ft 24Nm
(2.4 kgm)
Oil Inlet Tube Brace ............................................. 18 lb ft 24Nm
(2.4 kgm)
Oil Filter Housing Bolts .......................................... 18 lb ft 24 Nm
(2.4 kgm)
Rear Seal Retaining Bolts ......................................... 7 lb ft 9 Nm
(0.9 kgm)
Rocker Arm Bolts ............................................... 18 lb ft 24 Nm
(2.4 kgm)
Starter Retaining Bolts .......................................... 32 lb ft 43 Nm
(4.3 kgm)

1024-11
SPECIAL TORQUES (CONT'D)

Tachometer Drive Retaining Bolts ................................. 2 lb ft 3 Nm

(0.3 kgm)
Lifter Cover Bolts ............................................... 18 lb ft 24 Nm
(2.4 kgm)
Thermostat Housing Bolts ....................................... 18 lb ft 24 Nm
(2.4 kgm)
Timing Pin Retaining Bolts ........................................ 4 lb ft 5Nm
(0.5 kgm)
Fuel Shutoff Solenoid ........................................... 10 lb ft 15 Nm
(1.5 kgm)
Turbocharger Mounting Bolts .................................... 24 lb ft 32Nm
(3.2 kgm)
Turbocharger Drain Tube Bolts .................................. 18 lb ft 24Nm
(2.4 kgm)
Turbocharger Oil Supply (Both Ends) ............................ 13 lb ft 17Nm
(1.7 kgm)
Turbine Housing Bolts ........................................ 96 lb inch 11 Nm
(1.1 kgm)
Center Housing to Back Plate Bolts ............................ 481b inch 6Nm
(0.6 kgm)
Compressor Housing Bolts .................................... 48 lb inch 6Nm
(0.6 kgm)
Compressor Loc~ Nut ....................................... 120 lb inch 14 Nm
(1.4 kgm)
Thrust Bearing Screws (Torx Head) ........................... 36 lb i.nch 5Nm
(0.5 kgm)
Water Pump Mounting Bolts ..................................... 18 lb ft 24Nm
(2.4 kgm)
Coolant Inlet Bolts .........•.................................... 32 lb ft 43Nm
(4.3 kgm)
Valve Cover Bolts ............................................... 18 lb ft 24Nm
(2.4 kgm)

2000
ENGINE REMOVAL AND INSTALLATION
TABLE OF CONTENTS
Illustration of Engine Mounting ................................................................ 2000-2
Removal ..................................................................................... 2000-3
Installation .................................................................................. 2000-14
Written In Clear
And
Simple
English

2000-2
@4
®-3
5-~
850662
1. Front Engine Mount 3. Flat Washer 5. Self-Locking Nut

2. Bolt 4. Insulator
2000-3
REMOVAL
Because the only support for the torque con- 5. Remove the lower side panels from the ma-
verter is the engine, the torque converter must be chine.
removed with the engine.
1. Remove the guards below the engine and tor-

que converter.
a. Loosen the cap screws that hold the gu-

ards in position.
b. Before removing the cap screws, raise a

jack into contact with the guard to hold the
guard in position when the cap screws are re-
moved to prevent personal injury.
c. Remove the cap screws.

505316
d. Lower the guard and remove the guard

from under the machine.
6. Remove the cotter pin from each shaft at the
bottom of the grille.
7. Loosen and remove the cap screws that hold

the grille in position.
2. If the machine is a loader, raise the loader

frame and lower the strut onto the lift cylinder.
505318
3. If the machine is a dozer, lower the blade to the

floor.
8. Tilt the grille forward and remove the grille
from the mounting bracket.
4. Remove the upper side panels from the ma-
chine.
505314
2000-4
9. Loosen and remove the cap screws that fasten 14. Remove the left grille mount.
the mounting bracket to the frame.
15. Loosen and remove the nuts, lock washers,
and bolts that hold the right grille mount in posi-
tion.
16. Remove the right grille mount and cross brace

from the machine.
17. Loosen and remove the four nuts, lock wash-

ers, and cap screws that fasten the top plate to the
frame.
505322
10. Remove the mounting bracket.
11. Remove the radiator cap.
12. Drain the coolant from the radiator. Use clean

containers if the coolant is to be used again.
18. Loosen and remove the bolt and lock washer

that fasten the center support to the top plate.
19. Remove the top plate from the machine.
Drain Valve

and bolts that hold the left grille mount in position.
20. Loosen and remove the bolt and lock nut that
fasten the clamp on the tube for the oi I cooler to the
radiator shroud.
505326
2000-5
21. Loosen the clamp that fastens the bottom radi- 25. Loosen the clamp that fastens the top radiator
ator hose to the water pump. hose to the radiator.
505416
2. Water Pump
26. Remove the top radiator hose from the radia-

22. Remove the bottom radiator hose from the wa- tor.
ter pump.
27. Disconnect the tube from the fitting in the top
23. Disconnect the tube from the fitting in the bot- of the oil cooler.
tom of the oil cooler.
505420
24. Disconnect the coolant reservoir hose from the 28. Loosen and remove the cap screws, lock
radiator. washers, and flat washers that fasten the top rad ia-
tor supports to the frame. Move the hose from the
radiator to the coolant reservoir out of the way.
505423
2000-6
29. Connect acceptable lifting equipment to the 33. Remove the muffler support from the engine.
radiator.
30. Loosen and remove the nuts, flat washers, and

bolts that fasten the radiator to the radiator mounts.
1. Muffler Suppc:1 505437
34. Remove the extension pipe from the muffler.
31. Remove the radiator from the machine.
35. Remove the muffler from the engine. Remove

the hoods from the machine.
32. Remove the top radiator hose from the engine.
Muffler
2000-7
36. Remove the center support from the machine. 39. Remove the hose for the air cleaner from the
intake manifold or turbocharger.
40. Cover the opening in the intake manifold.
41. Disconnect the tube from the air cleaner.
37. Disconnect the fitting from the nozzle for the

ether injection system in the intake manifold.
1. Tube 505527
42. Loosen and remove the cap screws and lock

washers that fasten the air cleaner mounting
bracket to the machine.
505517
38. Loosen the clamp on the hose for the air

cleaner.
43. Remove the air cleaner, ether injection system,

and mounting bracket from the machine.
505529
2000-8
44. Remove the tie strap that fastens the coolant 48. Remove the coolant reservoir from the ma-
reservoir hose to the engine oil fill tube. chine.
49. Disconnect and remove the accelerator rod

from the fuel injection pump and the throttle eros-
shaft.
45. Loosen and remove the bolt, lock washer, flat

washer, and nut that fasten the clamp on the en-
gine oil dipstick tube to the bracket.
50. Close the fuel shutoff valve in the fuel lines.
51. Completely loosen the nut that holds the en-

gine temperature sensor in position. Remove the
ine temperature sensor from the
46. Install the bolt, lock washer, flat washer and

nut in the bracket.
47. Loosen and remove the bolts, lock washers,

and nuts that fasten the coolant reservoir to the To Fuel Pump
mounting bracket. From Fuel Injectors
52. Loosen the clamp on the hose to the fuel pump.

Remove the hose from the fuel pump.
53. Loosen the clamp on the hose from the fuel

injectors. Remove the hose from the fuel injector
line.
505535
2000-9
54. Remove the wires from the engine tempera- 57. Move the wiring harness out of the way.
ture switch for the ether in ection "'"'nclrn
58. Install the cap screws and rubber washers in
the holes that the cap screws and rubber washers
were removed from.
59. Disconnect the battery cable and wire from the

battery terminal. Disconnect the wire from the
switch terminal.
2. Switch Terminal
60. Disconnect the wires from the alternator.

Loosen and remove the cap screws from the
clamps that fasten the wiring harness to the en-
gine. Loosen and remove the cap screws that fas-
ten the circuit breaker mounting bracket to the
56. Remove the wire from the fuel injection pump.

Loosen and remove the cap screws and rubber
washers from the clamps that fasten the wiring
harness to the en ine.
1. Cap Screws for Circuit Breaker 505619
Mounting Bracket
2. Cap screws for Wiring Harness
3. Wires for Alternator
61. Install the cap screws in the holes that the cap
screws were removed from.
62. Move the wiring harness and circuit breaker

2. Clamps
mounting bracket out of the way.
2000-10
63. Loosen and remove the cap screws from the 67. Disconnect the hose from the top left of the
clamps that fasten the wiring harness to the torque torque converter housing.
converter housing.
64. Loosen and remove the cap screw from the

clamp that fastens the negative battery cable to the
torque converter housing.
68. Install a plug in the hose and a cap on the

fitting.

clamp that fastens the tube for the torque conver-
ter temperature gauge to the torque converter
housi
69. Disconnect the hose to the transmission pres-

sure gauge at the pressure regulator valve.

clamp that fastens the hose for the transmission
pressure gauge to the torque converter housing.
~
212106
212141
2000-11
70. Disconnect the hose from the elbow in the 73. Install a plug in the hose and a cap on the tee
pressure regulator valve. fitti
2. Cap
elbow.
74. Completely loosen the nut that holds the sen-
sor for the torque converter temperature gauge in
the tee fitting.
72. Disconnect the hose from the tee fitting on the

right side of the torque converter housing.
75. Remove the sensor from the tee fitting and put
the sensor out of the way.
2000-12
76. Loosen the clamp on the hose to the remote 81. Install a plug in the hose and a cap on the
breather at the fitting on top of the transmission. fitting.
Loosen and remove the fitting from the transmis-
sion. Connect a vacuum pump to this opening. If a
vacuum pump is not available, the oil must be
drained from the transmission.
77. Start the vacuum pump.
78. Disconnect the hose at the bottom of the tor-

que converter housing.
82. Loosen the clamp that fastens the suction hose

to the charging pump and remove the suction hose
from the fitting.

fitting.
in the hose and a cap on the
80. Disconnect the hose from the outlet of the

charg
215322
2000-13
84. Loosen and remove the nuts from the studs 88. Loosen and remove the self-locking nut, bolt,
that fasten the equipment pump to the torque con- flat washer, and insulator from both sides of the
verter housing. flywheel housing.
85. Pull the equipment pump from the torque con-

verter housing. Be careful not to damage the
splined shaft on the equipment pump.
86. Loosen and remove the cap screws that fasten

the drive shaft to the universal joint at the torque
converter.
1. Bolt, Flat Washer and Insulator 505625
89. Loosen and remove the self-locking nut, bolt,

flat washer, and insulator from the front engine
mount.
87. Use a piece of wire to hold the drive shaft out of

the way.
1. Self-Locking Nut 505627
90. Connect acceptable lifting equipment to the

engine. Use the lifting eyes that are a part of the
engine.
91. Remove the engine from the frame.
505632
NOTE: To remove the torque converter, see Sec-

tion 2001.
2000-14
INSTALLATION
1. Start the engine into the frame. 6. Install the top insulators and washers on the
side engine mounts. Install the bolt. Install the flat
washers and self-locking nuts. Tighten the self-
locking nuts.
2. Push the engine into the engine compartment.
3. Lower the engine into the frame and align the

engine mounts. 7. Align the drive shaft with the universal joint and
install the cap screws that hold the drive shaft in
4 Install a bottom tnsulator and washer between position.
the side engine mounts and the frame.
5. Install the top insulator and washer on the front

engine mount. Install the bolt. Install the flat
washer and self-locking nut. Tighten the self-lock-
ing nut.
8. Tighten the cap screws to 40 to 50 pound-feet

(54 to 68 N m, 6 to 7 kg/m).
212027
2000-15
9. Install the equipment pump in the torque con- 16. Remove the plug from the suction hose and the
verter housing. cap from the fitting in the charging pump.
10. Turn the flywheel as required to align the

splined shaft on the equipment pump with the drive
coupling.
11. Install the nuts on the studs that fasten the

equipment pump to the torque converter housing.
12. Make sure that the vacuum pump is connected

to the transmission.
13. Start the vacuum pump.
14. Loosen and remove the plug from the hose to

the bottom of the torque converter housing and the
cap from the fitting.
17. Install the suction hose and tighten the clamp.
18. Loosen and remove the plug from the hose to

15. Connect the hose to the fitting. the outlet of the charging pump and the cap from
the fitti
211808
215327
2000-16
19. Connect the hose to the charging pump. 22. Loosen and remove the plug from the hose
connected to the tee fitting and the cap from the tee
fittin .
215332
1. Plug 211843
20. Install the sensor for the torque converter tem- 2. Cap
perature gauge in the tee fitting on the right side of
the torque converter.
23. Connect the hose to the teE;) fitting.
21. Tighten the nut to hold the sensor in position.
24. Loosen and remove the plug from the large

hose connected to the pressure regulator valve and
the cap from the elbow.
211802
212111
2000-17
25. Connect the hose to the elbow. 28. Connect the hose to the fitting.
212109 212144
26. Remove the cap from the small elbow and the 29. Stop the vacuum pump.
plug from the hose to the transmission pressure
gauge and connect the hose to the elbow. 30. Install and tighten the cap screw that fastens
the clamp on the hose for the transmission pres-
sure gauge to the torque converter housing.
27. Remove the cap from the fitting in the top left of
the torque converter housing and the plug from the
hose connected to the fitting. 31. Install and tighten the cap screws that fasten
the clamp on the tube for the torque converter
temperature gauge to the torque converter hous-
ing.
212103
2000-18
32. Install and tighten the cap screw that fastens

the negative battery cable to the torque converter
housing.
1. Battery Cable and Wire 505623
2. Starter Switch
2;2223 36. Remove the cap screws and rubber washers

that fasten the clamps for the wiring harness to the
engine.
33. Remove the cap screws that fasten the wiring
harness and the circuit breaker mounting bracket 37. Put the wiring harness and clamps in position
to the engine. on the engine. Install the cap screws that fasten the
clamps on the wiring harness to the engine. Con-
34. Put the circuit breaker mounting bracket in nect the wire to the fuel injection pump.
position. Install the cap screws that fasten the cir-
cuit breaker mounting bracket to the engine. In-
stall and tighten the cap screws and rubber wash-
ers that fasten the clamps for the wiring harness to
the engine. Connect the wires to the alternator.
2. Clamps
38. Connect the hose for the engine oil pressure

1. Cap Screws for Circuit Breaker gauge to the fitting in the
Mounting Bracket
2. Cap Screws for Wiring Harness
3. Wires for Alternator
35. Connect the wire from the starter switch to the

starter. Connect the wire and the battery cable to
the battery cable terminal on the starter. See photo,
top of next column.
2000-19
39. Connect the wires to the engine temperature 43. Put the coolant reservoir in position. Install the
switch for the ether i bolts, lock washers, and nu~s that fasten the cool-
ant reservoir to the mounting bracket.
40. Install the hose on the fuel injector line. Tighten

the clamp. Install the hose on the fuel pump.
Tighten the clamp. Install the engine temperature 44. Install the bolt, lock washer, and nut that fas-
sensor in the engine. Tighten the nut that holds the tens the engine oil dipstick tube to the bracket.
temperature sensor in position.
1. Engine Temperature Sensor 505541

2. To Fuel Pump
3. From Fuel Injectors 45. Fasten the coolant reservoir hose to the engine
oil fill tube with a tie strap.
41. Open the fuel shutoff valve in the fuel lines. 46. Put the air cleaner, ether injection system, and
mounting bracket in position on the machine.
42. Connect the accelerator rod to the fuel injec-
tion pump and the throttle crosshaft.
2000-20
47. Install the cap screws and lock washers that 50. Connect the fitting to the nozzle for the ether
fasten the air cleaner mounting bracket to the ma- injection system in the intake manifold.
chine.
505522
51. Install the center support on the machine.

48. Connect the fitting for the air restriction indi-
cator to the air cleaner.
52. Install the muffler on the machine. Install the

hoods on the machine.
···········:·:.":.·:·::
49. Install the hose for the air cleaner on the intake
manifold or turbocharger. Tighten the clamp.
Muffler
505519
2000-21
56. Put the radiator in position in the machine.
54. Install the muffler support on the machine. 57. Install the nuts, flat washers, and bolts that
fasten the radiator to the radiator mounts. Tighten
the bolts to 50 to 60 pound-feet (68 to 82 N m, 6.9 to
8.3 kg/m).
55. Install the top radiator hose on the engine. 505344
Tighten the clamp.
58. Remove the lifting equipment from the radia-

tor.
59. Install the cap screws, lock washers, and flat

washers that fasten the top radiator supports to the
frame. The clamp on the hose from the radiator to
the coolant reservoir must be installed as shown.
See illustration on page 18, Section 2001.
505423
2000-22
60. Connect the tube to the fitting at the top of the 63. Connect the tube to the fitting in the bottom of
oil cooler. the oil cooler.
61. Install the upper radiator hose on the radiator. 64. Install the bolt and self-locking nut that fastens
Tighten the clamp. the clamp on the tube for the oil cooler to the
radiator shroud.
65. Install the lower radiator hose on the water

pump. Tighten the clamp.
62. Connect the hose from the coolant reservoir to

the radiator shown. p
2. Water Pump
66. Fill the radiator. If new coolant is being in-

stalled, the coolant must be at least half permanent
antifreeze. Install the radiator cap. Fill the coolant
reservoir to the FULL mark.
505414
2000-23
67. Make sure the crankcase has been filled with

the correct engine oil. See Section 1002.
68. If the transmission was drained, see Section

1002 and fill the transmission. If the old transmis-
sion fluid is to be used, the transmission fluid must
be filtered.
69. Start the engine and run the engine at low idle.
Check to make sure that the gauges show the cor-
rect indications. Check for leaks. Stop the engine.
70. Put the top plate in position on the machine.
73. Put the mounting bracket in position on the

frame. Install the cap screws that fasten the mount-
ing bracket to the frame.
505334
71. Install the bolt and lock washer that fasten the
center support to the top plate. Install the four nuts,
lock washers, and cap screws that fasten the top
plate to the frame.
74. Engage the shafts on the grille with the holes in

the mounting bracket. Raise the grille into posi-
tion.
505330
72. Put the right grille mount and cross brace in

position on the frame. Install the nuts, lock wash-
ers, and bolts that fasten the grille mount and cross
brace to the frame. Put the grille mount in position
on the frame. Install the nuts, lock washers, and
bolts that fasten the grille mount and cross brace to
the frame. See photo, top of next column.
2000-24
75. Hold the grille in position and install the cap 79. Install the guards below the engine, torque
screws that fasten the grille to the radiator and converter, and transmission.
grille mounts.
a. Use the jack to raise a guard into position.
505318
509306
76. Install the cotter pin in each shaft at the bottom b. Install, but do not tighten, the cap screws
of the grille. that fasten the guard in position.
77. Install the lower side panels on the machine. c. Install the remainder of the guards.
Tighten the cap screws.
d. Tighten the cap screws that hold each
guard in position.
80. If the machine is a loader, fasten the strut to the

loader frame and lower the loader frame.
50531G
78. Install the upper side panels on the machine.

505314
2001
ENGINE ACCESSORIES
TABLE OF CONTENTS
Torque Converter ...................... 2001-2 General Information .................. 2001-9
Removal ............................. 2001-2 Operating Procedure ................. 2001-9
Installation ........................... 2001-2 Troubleshooting ..................... 2001-9
Air Cleaner ............................ 2001-4 Illustration of Ether Injection

System ........................... 2001-11
Service Interval ...................... 2001-4
Radiator .............................. 2001-12
Precleaner ........................... 2001-4
Removal ............................ 2001-12
Restriction Indicator .................. 2001-4
Installation .......................... 2001-15
Dust Valve and Wing Nut ............. 2001-4
Illustration of Radiator ............... 2001-18
Cleaning the Primary Element ......... 2001-4
Turbocharger ......................... 2001-19
Secondary Element ................... 2001-4
Priming the Turbocharger ........... 2001-19
Illustration of Air Cleaner Installation .. 2001-5
Stopping the Engine ................. 2001-19
Illustration of Air Cleaner Assembly and
Restriction Indicator ................ 2001-6 Causes of Turbocharger Failure ...... 2001-19
Mufflers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2001-7 Illustration of Turbocharger

Installation ........................ 2001-20
Illustration of Muffler Installation Without
Turbocharger ...................... 2001-8 Removal ............................ 2001-21
Ether Injection System .................. 2001-9 Installation .......................... 2001-21
Written In Clear
And
Simple
English

2001-2
TORQUE CONVERTER
Removal 7. Remove the torque converter from the engine.
This procedure is for separating the engine

and torque converter following removal from the
machine.

the cover to the left front of the flywheel housing.
Remove the cover.
2. Turn the crankshaft until one of the cap screws

that hold the flexplate is in the opening in the fly-
wheel housing.
3. Loosen and remove the cap screw.
Installation
1. Move the torque converter into alignment with
the flywheel housing.
2. Install a 4 inch (102 mm) M10 x 1.5 stud in the

flex plate as shown.
4. Repeat steps 2 and 3 until12 cap screws have

been removed.
5. Fasten acceptable lifting equipment to the tor-

que converter.

the torque converter to the flywheel housing.
3. Make sure a hole in the flywheel for one of the
cap screws that hold the flexplate is in the opening
in the flywheel housing. Align the stud with this
hole.
2001-3
4. Push the torque converter towards the engine. 6. Remove the stud from the opening in the fly-
wheel housing.
5. Align the torque converter with the flywheel

housing and install the cap screws that fasten the 7. Remove the lifting equipment.
torque converter to the flywheel housing. Do not
install cap screws in holes used to fasten clamps 8. Install and tighten the cap screw that fastens
and cables to the torque converter housing. the flywheel to the flex plate. Tighten the cap screw
to 29 to 36 pound-feet (39 to 49 N m, 4 to 5 kg/m).
9. Turn the crankshaft so that another cap screw

can be installed and tightened.
10. Repeat steps 8 and 9 until the 12 cap screws

have been installed and tightened.
11. Put the cover in position over the opening in

the flywheel housing. Install and tighten the cap
screws that fasten the cover to the flywheel hous-
ing.
2001-4
AIR CLEANER
Service Interval Cleaning the Primary Element
The primary element must be cleaned or re- It is recommended that the primary element be
placed any time that the red band in the restriction cleaned by washing. Washing will remove more dirt
indicator stays in view all the time. than other methods.
Precleaner NOTE: A new primary element must be in-

stalled yearly or after the primary element has been
Clean the bowl of the precleaner when the dirt cleaned six times. The date of the manufacture is
is at the mark on the side of the bowl (approximate- on the end cap of the primary element. Do not
ly 1/2 inch (13 mm) from the top of the bowl). install a primary element that is more than two
years old.
Clean the body of the precleaner as required.
Use Case Air Filter Element Cleaner (part no.
Restriction Indicator A40190) to wash the primary element. DO NOT
install the primary element until the primary ele-
If the red band in the restriction indicator is in ment is dry. DO NOT use compressed air to dry the
full view, clean or replace the air cleaner elements. primary element.
Do not run the engine when the red band is in full
view. The use of compressed air to clean the primary
element is permitted when washing is not avail-
After you service the air cleaner you must re- able. Use no more than 30 psi (206 kPa) at the
move the red band from view. Push the button on nozzle and hold the nozzle at least one inch (25
the restriction indicator and the green band will be mm) from the primary element. Move the nozzle
in full view again. along each ridge on the inside of the primary ele-
ment.
Restriction Indicator Check
Inspect the primary element when the primary
In this check, the red band must be in full view element is clean and dry. Use a light inside the
at 30 inches of water (7.5 kPa). primary element and look for holes in the paper.
Also check to see if the metal covering is bent. If
1. Check the tube between the filter fitting and the there are holes in the paper or the metal covering is
restriction indicator for cracks, holes, and loose bent, install a new primary element.
connections.
NOTE: Inspect a new primary element the
2. If a manometer is available: same way. Do not use a primary element that is
damaged.
a. Remove the restriction indicator from the
instrument panel. Secondary Element
b. Connect the hose from the manometer to DO NOT clean the secondary element.
the restriction indicator.
Replace the secondary element.
c. Actuate the manometer.
1. With every third change of the primary ele-
d. Turn the vacuum control until the red band ment.
in the restriction indicator is in full view.
2. When the secondary element is more than two
e. If the vacuum indication is not as specified, years old. The date that the secondary element was
install a new restriction indicator. made is on one end of the secondary element.
Dust Valve and Wing Nut 3. When the secondary element is damaged.
Check the dust valve and end cap wing nut 4. When the red band in the restriction indicator
every 50 hours of operation. Make sure that the end stays in view after the primary element has been
cap is tight. Make sure that there is no obstruction cleaned or replaced.
inside the dust valve.
2001-5
I
A
1. Precleaner 3. Bowl 5. Air Cleaner Assembly 7. Hose (Used Without

2. Cap 4. Body 6. Hose (Used With Turbocharger)
Turbocharger)
Air Cleaner Installation

2001-6
A
0
85011111
1. Body 3. Primary Element 5. End Cap

2. Secondary Element 4. Dust Valve 6. Restriction Indicator
Air Cleaner Assembly and Restriction Indicator

2001-7
MUFFLERS
Cleaning the Spark Arrester Muffler
The spark arrester muffler must be cleaned
after every 100 hours of operation. See illustration
on next page.
1. If the machine is a loader, raise the loader 1

frame and lower the strut onto the lift cylinder.
2. Stop the engine.
3. Remove the side panel from the left side of the

engine compartment.
4. Remove the pipe plugs from the left side of the

spark arrester muffler. If a new pipe plug is re-
quired, use a pipe plug made of brass.
5. Turn the fuel shutoff switch to the OFF position.

2
6. Put the master disconnect switch in the ON
position.
7. Have another person close the opening in the

exhaust pipe.
8. Actuate the starter for 30 seconds. Soot and

carbon in the spark arrester muffler will be re-
moved by the force of the exhaust from the engine.
9. Install the pipe plugs.
10. Install the side panel.
1. Exhaust Pipe 3. Tube

2. Muffler
Muffler Installation With Turbocharger

2001-8
~
i
I@
13
~
~4
850683
1. Standard Exhaust Pipe 6. Spark Arrester Exhaust Pipe

2. Standard Muffler 7. Spark Arrester Muffler
3. Adapter 8. Pipe Plug (2) (Brass Only)
4. Gasket 9. Flanges Installed on Top of Hood and
5. Cap, Used With Spark Arrester Muffler Only Touching Hood
Muffler Installation Without Turbocharger

2001-9
ETHER INJECTION SYSTEM

4. Push in and hold the starter button and push in
and release the cold start button. The cold start
button can be pushed in and released two times
during each starting cycle. If the engine will not
start, check to make sure that there is ether in the
container.
IMPORTANT: Before you replace the starting

fluid container, read the warnings and instructions
on the container.
Troubleshooting
WARNING: Oo not make repairs to the
/'>.. ether InJectiOn system near an open flame
. . or while smok1ng Ether burns easily.
47-29
The temperature of the engine block coolant

must be below 40° F (4.4° C) to find problems in the
ether injection system. If the temperature of the
engine block coolant is above 40° F (4.4° C) the
thermostat could be in the OPEN position and will
not let current flow to the solenoid valve.
1. Check for damage to the tube between the

General Information solenoid valve and the nozzle. Make sure that the
fittings are tight.
See the illustration on page 2001-11.
2. Check the wiring for loose connections or cor-
When the starter button is pushed in and held, rosion on the connections. Make sure that the
and the cold start button is pushed in, current flows wires are not broken.
through the thermocouple when the temperature
of the engine coolant is 40 to 75° F (4.4 to 24.0° C) or 3. Disconnect the tube from the nozzle.
colder. From the thermocouple current flows to the
solenoid valve which opens the valve in the starting 4. Loosen and remove the nozzle. Check to see
fluid container. The starting fluid flows through the that both holes in the nozzle are open.
tube and nozzle into the intake manifold.
5. This is a mark on one flat on the hex on the
When the starter button is pushed in and held, nozzle. Install and tighten the nozzle so that this flat
each time the cold start button is pushed in and is horizontal (top or bottom).
released a measured amount of starting fluid is
sent to the intake manifold. 6. Install a new container of starting fluid.
7. Disconnect the wiring from the thermocouple.

Operating Procedure
8. Connect a jumper wire to the terminals in the
1. Apply the parking brake.
wiring connector.
2. Move all transmission control levers to neutral. 9. You will need another person to help do this
step.
3. Turn the master disconnect switch to the ON
position and make sure that the engine run switch a. Turn the master disconnect switch to the
is in the RUN position. ON position and the engine run switch to the
OFF position.
2001-10
b. Hold the end of the tube away from your 11. If there was no odor of ether at the end of the
body. tube:
c. Have the other person push in and hold the a. At the ground connection, connect a 24
starter button and push in and release the cold volt test lamp to the wire from the cold start
start button several times. Then release the switch.
starter button.
b. Have the other person push in and hold the
10. If there was the odor of ether at the end of the starter button and push in and release the cold
tube, replace the thermocouple. start button several times.
12. If the test lamp illuminated, replace the sole-

noid valve.
13. If the test lamp did not illuminate, the problem

is in the wiring.
2001-11
--- 11
~~
13
)
850684
1. Thermocouple 6. Nut 10. Compression Nut

2. Reducer 7. Ground Wire 11. Nylon Tube
3. Valve Assembly 8. Elbow 12. Nozzle
4. Starting Fluid Container 9. Sleeve 13. Cold Start Switch
5. Bolt
Ether Injection System

2001-12
RADIATOR
Removal 6. Loosen and remove the cap screws that hold
the grille in position.
1. If the machine is a loader, raise the loader from
and lower the strut onto the lift cylinder.
2. If the machine is a dozer, lower the blade to the

floor.
3. Remove the upper side panels from the ma-

chine.
7. Tilt the grille forward and remove the grille

from the mounting bracket.
4. Remove the lower side panels from the ma-

chine.

the mounting bracket to the frame.
5. Remove the cotter pin from each shaft at the

bottom of the grille.
2001-13
9. Remove the mounting bracket. 16. Loosen and remove the four nuts, lock wash-
ers, and cap screws that fasten the top plate to the
10. Remove the radiator cap. frame.
11. Drain the coolant from the radiator. Use clean

containers if the coolant is to be used again.
1. Plastic Tube - Connect to 505324

17. Loosen and remove the bolt and lock washer
Drain Valve that fasten the center support to the top plate.
12. Loosen and remove the nuts, lock washers, 18. Remove the top plate from the machine.
and bolts that hold the left grille mount in position.
19. Loosen and remove the bolt and lock nut that
13. Remove the left grille mount. fasten the clamp on the tube for the oil cooler to the
radiator shroud.
and bolts that hold the right grille mount in posi-
tion.
15. Remove the right grille mount and cross brace

from the machine.
2001-14
20. Loosen the clamp that fastens the bottom radi- 24. Loosen the clamp that fastens the top radiator
ator hose to the water pump. hose to the radiator.
Water Pump
25. Remove the top radiator hose from the radia-

21. Remove the bottom radiator hose from the wa- tor.
ter pump.
26. Disconnect the tube frorn the fitting in the top
22. Disconnect the tube from the fitting in the bot- of the oil cooler.
tom of the oil cooler.
27. Loosen and remove the cap screws, lock

23. Disconnect the coolant reservoir hose from the washers, and flat washers that fasten the top radia-
radiator. tor supports to the frame. Move the hose from the
radiator to the coolant reservoir out of the way.
2001-15
28. Connect acceptable lifting equipment to the 2. Install the nuts, flat washers, and bolts that
radiator. fasten the radiator to the radiator mounts. Tighten
the bolts to 50 to 60 pound-feet (68 to 82 N m, 7 to 8
29. Loosen and remove the nuts, flat washers, and kg/m).
bolts that fasten the radiator to the radiator mounts.
3. Remove the lifting equipment from the radia-

tor.
30. Remove the radiator from the machine.
4. Install the cap screws, lock washers, and flat
washers that fasten the top radiator supports to the
frame. The clamp on the hose from the radiator to
the coolant reservoir must be installed as shown.
Installation
1. Clamp 505423
1. Put the radiator in position in the machine.
5. Connect the tube to the fitting at the top of the
oil cooler.
2001-16
6. Install the upper radiator hose on the radiator. 9. Install the bolt and self-locking nut that fastens
Tighten the clamp. the clamp on the tube for the oil cooler to the
radiator shroud.
10. Install the lower radiator hose on the water

pump. Tighten the clamp.
7. Connect the hose from the coolant reservoir to

the radiator as shown.
11. Put the top plate in position on the machine.
8. Connect the tube to the fitting in the bottom of

the oil cooler.
12. Install the bolt and lock washer thatfastens the

center support to the top plate. Install the four nuts,
lock washers, and cap screws that fasten the top
plate to the frame.
2001-17
13. Put the right grille mount and cross brace in 17. Put the mounting bracket in position on the
position on the frame. Install the nuts, lock wash- frame. Install the cap screws that fasten the mount-
ers, and bolts that fasten the grille mount and cross ing bracket to the frame.
brace to the frame. Put the left grille mount in posi-
tion on the frame. Install the nuts, lock washers,
and bolts that fasten the grille mount and cross
brace to the frame.
18. Engage the shafts on the grille with the holes in

the mounting bracket. Raise the grille into posi-
tion.
14. Fill the radiator. If new coolant is being in-

stalled, the coolant must be at least half permanent
antifreeze. Install the radiator cap.
19. Hold the grille in position and install the cap

screws that fasten the grille to the radiator and
grille mounts.
15. Fill the coolant reservoir to the FULL mark. Start

the engine and run the engine at low idle. Check for
leaks. Let the engine run until the coolant is at
operating temperature .
.16. Stop the engine. When the engine is cool,

check the level in the coolant reservoir. Add cool-
ant, if necessary.
2001-18
20. Install the cotter pin in each shaft at the bottom 22. Install the upper side panels on the machine.
of the grille. Tighten the cap screws.
21. Install the lower side panels on the machine.

23. If the machine is a loader, fasten the strut to the

loader frame and lower the loader frame.
850685
1. Coolant Bottle 3. Top Radiator Hose 5. Drain Valve

2. Radiator 4. Bottom Radiator Hose
Radiator
2001-19
TURBOCHARGER
Priming the Turbocharger IMPORTANT: If the engine stops running
when the engine is running at a high speed, start
If the weather is very cold, if the turbocharger the engine immediately. If the engine is not started
has been removed, or the engine has not been run immediately, the turbocharger can be damaged.
for 3 or more months the turbocharger must be
filled with oil before the engine is started. Stopping the Engine
1. Apply the parking brake. 1. Apply the parking brake.
2. Be sure that the track speed control levers are 2. Move the track speed control levers to the N
in the N position. position.
3. Make sure that the fuel shutoff switch is in the 3. Run the engine at low idle for two minutes.
OFF position.
4. Put the fuel shutoff switch in the OFF position.
4. Turn the master disconnect switch to the ON
position. 5. Turn the master disconnect switch to the OFF
position.
5. Push in and hold the starter button until the
engine oil pressure gauge indicates engine oil Causes of Turbocharger Failure
pressure.
Finding the cause of turbocharger failure is
6. Turn the fuel shutoff switch to the ON position. just as important as removing and installing the
turbocharger correctly. See Section 2565 for cause
7. Start the engine and run the engine at low idle of turbocharger failure.
for two minutes. After two minutes, the engine can
be run at any speed.
2001-20
....-"\
/ I
/.....- I
I / I
\....,...... I
I
I
1 I
TO OIL
FILTER HEAD
FRONT OF
ENGINE
TO CYLINDER BLOCK
-
1. Turbocharger 6. Exhaust Elbow 11. Intake Manifold
2. Special Clamp 7. Bracket 12. Clamp
3. Nut B. Exhaust Manifold 13. Oil Supply Hose
4. Gasket 9. Intake Tube 14. Oil Return Tube
5. Stud 10. Intake Hose
Turbocharger Installation
2001-21
Removal 21. Remove the gasket from the oil return tube (or
turbocharger).
1. If the machine is a loader, raise the loader
frame and lower the strut onto the lift cylinder. 22. Check the condition of the hoses connected to
the turbocharger. If a hose is damaged or is hard,
2. If the machine is a dozer, lower the blade to the install a new hose.
floor.
Installation
3. Loosen the cap screws at the bottom of the left
side panel. 1. Put a new gasket on the exhaust manifold.
4. Loosen and remove the cap screws at the top of 2. Push the turbocharger into the intake hose on
the left side panel. the left side of the machine.
5. Remove the left side panel. 3. Push the turbocharger onto the exhaust elbow
for the muffler.
6. Loosen the cap screws at the bottom of the
right side panel. 4. Tighten the nut on the special clamp that fas-
tens the exhaust elbow to the turbocharger to 55 to
7. Loosen and remove the cap screws at the top of 60 pound-inches (6.2 to 6.8 N m, 0.6 to 0.7 kg/m).
the right side panel.
5. Install the nuts on the studs that fasten the
8. Remove the right side panel. turbocharger to the exhaust manifold. If a new nut
is needed, the nut must be the nut specified in the
9. Loosen and remove the cap screws that hold parts catalog.
the left half of the hood in position on the machine.
6. Put a new gasket on the flange on the return oil
10. Remove the left hood. tube.
11. Loosen the clamp on the air cleaner hose at the 7. Install and tighten the cap screws that fasten
rear of the turbocharger. the return oil tube to the turbocharger.
12. Remove the hose from the turbocharger. 8. Connect the oi I supply hose to the fitting on the
top of the turbocharger.
13. Loosen the clamp on the intake hose on the left
side of the turbocharger. 9. Put Pliobond on the ID of the air cleaner hose
connected to the rear of the turbocharger.
14. Loosen the special clamp that fastens the ex-
haust elbow to the turbocharger. 10. Install the air cleaner hose on the rear of the
turbocharger.
15. Disconnect the oil supply hose from the fitting
in the top of the turbocharger. 11. Tighten the clamp at the rear of the turbochar-
ger.
the oil return tube to the bottom of the turbochar- 12. Tighten the clamp on the left side of the turbo-
ger. charger.
17. Loosen and remove the nuts from the studs 13. Install the left hood.
that fasten the turbocharger to the exhaust mani-
fold. 14. Install and tighten the cap screws that hold the
left hood in position.
18. Hit the turbocharger with a soft hammer to
break the seal of the gasket. 15. See Priming the Turbocharger on page 2001-
19 to fill the turbocharger with oil. Then start the
19. Remove the turbocharger. engine and check for oil leaks.
20. Remove the gasket from the exhaust manifold 16. Install the left side panel.
(or turbocharger).
2001-22
17. Install and tighten the cap screws at the top of 20. Install and tighten the cap screws at the top of
the left side panel. the right side panel.
18. Tighten the cap screws at the bottom of the left 21. Tighten the cap screws at the bottom of the
side panel. right side panel.
19. Install the right side panel. 22. If the machine is a loader, raise the loader
frame and fasten the strut to the loader frame.
Lower the loader frame.
2002
ENGINE STALL TESTS
TABLE OF CONTENTS
Stall Tests . ............................. 2002-2 Hydraulic System .................. 2002-3
Specifications ........................ 2002-2 Test No. 1 -Torque Converter and Hydraulic

Stall Together ...................... 2002-3
Procedure to Heat the Oil ............. 2002-2
Test No.2- Torque Converter Stall .... 2002-3
Torque Converter .................. 2002-2
Test No.3- Hydraulic Stall ............ 2002-4
Written In Clear
And
Simple
English

CASE CORPORATION
2002-2
STALL TESTS
During these tests the engine runs at full throt- show you if the cause for bad performance is in any
tle and works against the torque converter, the one or more than one of the following parts: (1)
hydraulic system, or both the torque converter and engine, (2) torque converter or transmission, (3)
the hydraulic system. The results of these tests will hydraulic system.
Specifications
Low idle ...................................................................... 750 to 800 rpm (r/min)
Full throttle (no load) ........................................................ 2095 to 2175 rpm (r/min)
Temperature of the torque converter oil ....................... Center of the green area on the gauge for
the torque converter temperature.
Temperature of the hydraulic oil ............................................. 125 to 175°F (51 to 79°C)
Stall Speeds
100 hours or less 100 hours or more
Hydraulic stall
All machines ........................... 2000 rpm (r/min) min. 2000 rpm (r/min) min.
Torque converter stall
All dozers . . . . . . . . . . . . . . . . . . . . . . . . . . . 1825-1915 rpm (r/min) 1900 to 1990 rpm (r/min)
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 to 2040 rpm (r/min) 2020 to 2040 rpm (r/min)
Combined stall
Dozer............................... 1275 -1520 rpm (r/min) 1350- 1520 rpm (r/min)
Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310 -1570 rpm (r/min) 1400-1570 rpm (r/min)
Procedure to Heat the Oil h. Repeat steps 1a through 1 g until the park-
ing brake keeps the machine from moving with
Torque Converter the engine running at full throttle.
1. Check the parking brake to make sure that the 2. Return the track speed levers to neutral.
parking brake will keep the machine from moving
while the oil in the torque converter is being 3. Run the engine at low idle.
heated.
4. Look at the gauge for the torque converter
a. Apply the parking brake. temperature. The needle in the gauge must be in
the center of the green area on the gauge.
b. Start and run the engine at low idle.
5. If the temperature is not correct, move the track
c. Put the range control lever in the Hi posi- speed control levers to the Hi position.
tion.
6. Increase the engine speed to full throttle. Con-
d. Put the track speed control levers in the Hi tinue to run the engine at full throttle for two min-
position. utes.
e. Put the direction control levers in the F 7. Return the track speed control levers to neu-
position. tral.
f. Slowly increase the engine speed to full 8. Run the engine at full throttle for 30 seconds.
throttle. If the parking brake does not keep the Decrease the engine speed to low idle.
machine from moving, stop the engine imme-
diately. 9. Repeat steps 4 through 8 until needle in the
gauge for the torque converter temperature stays
g. See Section 7001 and adjust the parking in the center of the green area of the gauge.
brake.
2002-3
Hydraulic System 7. Hold the loader control lever in the Rollback

position or the blade control lever in a Tilt position.
1. Apply the parking brake.
8. Look at the tachometer. Make a record of the
2. Start and run the engine at full throttle. engine speed.
3. If the machine is a loader: 9. Return the dozer or loader control lever to neu-
tral. Decrease the engine speed to low idle.
a. Put the loader control lever in the Rollback
position. 10. Return the track speed levers to neutral.
b. Hold the loader control lever in the Roll- 11. Stop the engine.
back position for 15 seconds. Then put the
loader control lever in neutral for 30 seconds. Understanding the Results of the Test
c. Repeat steps 3a and 3b until the tempera- 1. If the engine speed was correct, the engine,
ture of the hydraulic oil is between 125 to torque converter and transmission, and the hy-
175° F (51 to 79° C). If a thermometer is not draulic system are probably good.
available, feel the tube connected to the inlet of
the equipment control valve. The tube must be 2. If the engine speed was not as specified, do
very warm. Test No.2 and Test No.3.
4. If the machine is a dozer: Test No.2- Torque Converter Stall

a. Put the blade control lever in a Tilt posi- 1. Apply the parking brake.
tion.
2. Start the engine and run the engine at low idle.
b. Hold the blade control lever in a Tilt posi-
tion for 15 seconds. Then put the blade control 3. The range control lever stays in the Hi position.
lever in neutral for 30 seconds.
4. The direction control levers stay in the F posi-
c. Repeat steps 4a and 4b until the tempera- tion.
ture of the hydraulic oil is between 125 to
175° F (51 to 79° C). If a thermometer is not 5. Move the track speed control levers to the Hi
available, feel the tube connected to the inlet of position.
the equipment control valve. The tube must be
very warm. 6. Increase the engine speed to full throttle.
Test No. 1 -Torque Converter and 7. Look at the tachometer. Make a record of the
Hydraulic Stall Together engine speed.
8. Reduce the engine speed to low idle and return

1. Apply the parking brake. the track speed control levers to neutral.
2. Start the engine and run the engine at low idle. 9. Stop the engine.
3. Move the range control lever to the Hi position. Understanding the Results of the Test
4. Move the track speed control levers to the Hi 1. If the engine speed was correct, the engine and
position. torque converter and transmission are probably
good.
5. Move the direction control levers to the F posi-
tion. 2. If the engine speed was below the specified
speed, do Test No.3.
6. Increase the engine speed to full throttle. If the
parking brake does not keep the machine from
moving, stop the engine. Adjust the parking brake.
See Section 7001.
2002-4
3. If the engine speed was above the specified 7. Decrease the engine speed to low idle and stop
speed, the torque converter, the transmission or the engine.
both the torque converter and the transmission are
probably the cause. See Section 6002 for informa- Understanding the Results of the Test
tion on troubleshooting.
1. If tt}e engine speed was correct, the engine and
Test No. 3 - Hydraulic Stall the hydraulic system are good.
1. Apply the parking brake. 2. If the engine speed was above the specified
speed, the hydraulic system is probably the cause.
2. Start and run the engine at 1000 rpm (r/min). See Section 8002 for troubleshooting information.
3. Hold the loader control lever in the Rollback 3. If the engine speed was below the specified
position or the blade control lever in a Tilt position. speed in Test No.1, Test No.2, and Test No.3, the
engine is probably the cause.
4. Increase the engine speed to full throttle.
5. Look at the tachometer. Make a record of the

engine speed.
6. Put the loader control lever in neutral or the

blade control lever in neutral.
Section
2415
CYLINDER HEAD AND VALVE TRAIN
Written In Clear
And
Simple
English
All measurements and the checks must be made with metric tools to make sure
of an accurate reading when inspecting parts.
CASE CORPORATION Rae 8-26071 Printed in U.S.A.

October. 1984 (Revised March. 1985)
2415-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................ 3
SPECIAL TORQUES .............................................................................. 4
SPECIAL TOOLS ................................................................................. 5
SERVICING THE CYLINDER HEAD AND VALVE TRAIN

Cylinder Head Removal ....................................................................... 6-16
Cylinder Head Disassembly ............................................ , ..................... 17-19
Cylinder Head Assembly ..................................................................... 34,35
Rocker Arm Disassembly .................................................................... 36,37
Rocker Arm Assembly .......................................................................... 38
Cylinder Head Installation ................................................................... 39-45
EXPANSION PLUG REPLACEMENT

Cylinder Head Installed ......................................................................... 20
Cylinder Head Removed ........................................................................ 21
VALVE GUIDE REPLACEMENT ................................................................... 22
INSPECTION OF THE VALVE AND VALVE SEATS .............................................. 23-25
VALVE SEAT INSTALLATION .................................................................... 26
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS ............................... 27,28
DIAGNOSIS OF DIFFERENT DYE PATTERNS .................................................. 29-33
LOCATING TOP CENTER ........................................................................ 46
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE ...................................... 47-51
·.
Rae 8-26071 Revised 3-85 Printed in U.S.A

2415-3
SPECIFICATIONS
Valve Guide Installation Specifications:
Valve Guide Diameter ......................................................... 14.026 to 14.038 mm

Diameter of Bore .............................................................. 13.987 to 14.013 mm
Press Fit ........................................................................ 0.013 to 0.051 mm
Installed Height ................................................................. 11.25 to 11.75 mm
Exhaust Valve Insert Specifications:
Diameter of Insert ............................................................. 43.713 to 43.739 mm

Diameter of Bore .............................................................. 43.647 to 43.663 mm
Depth of Bore .........•........•................................................ 10.10 to 10.30 mm
Press Fit ......................................................................... 0.05 to 0.092 mm
Intake Valve Insert Specifications:
Diameter of Insert .........•................................................... 47.063 to 47.089 mm

Diameter of Bore ..........•................................................... 46.987 to 47.013 mm
·Depth of Bore ................................................................... 10.30 to 10.50 mm
Press Fit ......................................................................... 0.05 to 0.102 mm

2415-4
SPECIAL TORQUES
Belt Tensioner Bracket Bolts (Allen head) ......................... 18 lb ft 24 Nm
(2.4 kgm)
Belt Tensioner Bolt .............................................. 32 lb ft 43 Nm

(4.3 kgm)
Exhaust Manifold Bolts .......................................... 32 lb ft 43 Nm

(4.3 kgm)
Fan Belt Pulley Bracket Bolts .................................... 18 lb ft 24 Nm

(2.4 kgm)
Fan Belt Pulley Bolts, Grade 8.8 .................................. 18 lb ft 24 Nm

(2.4 kgm)
Fan Belt Pulley Bolts, Grade 10.9 .•............................... 25 lb ft 34Nm

(3.4 kgm)
Fuel Filter Housing Nut .......................................... 24 lb ft 32 Nm

(3.2 kgm)
Injector Leak Off Fitting .......................................... 4 lb ft 6 Nm

(0.6 kgm)
Injector Cap Nut ........................................... 41 to 44 lb ft 55 to 60 Nm

(5.5 to 6.0 kgm)

(12.6 kgm)
Intake Manifold Cover Bolts ...................................... 18 lb ft 24 Nm

(2.4 kgm)
Rocker Arm Bracket Bolts ....................................... 18 lb ft 24 Nm

(2.4 kgm)
Valve Cover Bolts ............................................... 18 lb ft 24 Nm

(2.4 kgm)

(2.4 kgm)
Alternator Bracket Bolts ......................................... 18 lb ft 24 Nm

(2.4 kgm)
Lift Bracket Bolts (Rear) ......................................... 57 lb ft 77 Nm

(7.7 kgm)

2415-5
SPECIAL TOOLS
VALVE ADJUSTING TOOL
CAS-10240 VALVE SPRING COMPRESSOR

CAS-1357 VALVE SPRING TESTER
CAS-1694 INJECTION
BORE CLEANER
DEPTH MICROMETER
CAS-1 0064-1 M
CAS-1690 ENGINE TURN OVER TOOL

0 TO 25 MM MICROMETER
CAS-10285M
VALVE GUIDE REAMER

CAS-1743
CAS-10087 BORE GAUGE SET
CAS-1066A WRENCH TORQUE WRENCH LB FT

TORQUE WRENCH INCH POUND
FEELER GAUGE METRIC
~~:.··~~
~ .. \."_:!,
~ ...., ... ~
THREAD SEALANT WITH TEFLON - 817503 6 ml TUBE
A157B BUSHING DRIVER SET

"SNAP-ON"

2415-6
SERVICING THE CYLINDER HEAD AND VALVE TRAIN

Cylinder Head Removal
STEP 1
Case 6T-590 engine
Case 6TA-590 engine
Case 6-590 engine.
Remove the fan pulley bolts and the fan pulley.

2415-7
STEP 5
Remove the bracket bolts. Remove the belt tensioner bolt.
Remove the fan pulley bracket. Remove the belt tensioner.

2415-8
STEP 9
4/'$>.._ fJ
Remove the Allen head bolts from the belt ten- See section 2465 to remove the turbocharger.
sioner bracket.
STEP 10
Remove the bolts that hold the alternator and re-

Remove the belt tensioner bracket. move the alternator.

2415-9
STEP 16
Remove the alternator bracket bolts. Remove the thermostat housing assembly.
STI;P17
Remove the alternator bracket. Remove the exhaust manifold bolts.
Remove the thermostat housing bolts.

2415-10
STEP 18 STE~ 21
Remove the exhaust manifold.
Remove the exhaust manifold gaskets and clean Remove the leak off fitting gaskets.
the exhaust manifold mounting surface.
Remove the leak off line.

Disconnect the fuel supply line from the injectors,
and install dust covers on the injectors.

2415-11
Remove the bolts and clamps that hold the fuel Install protective covers on the injection pump out-
lines. let lines and the injection lines.
Disconnect the fuel line from the fuel injection Loosen the nut on the injectors.
pump.
NOTE: The injector must not rotate in the bore of
the cylinder head. This will damage the cylinder
head.
STEP 29
Remove the fuel lines.
Remove the injectors from the cylinder head.
NOTE: Make sure the injector seal is removed

from the cylinder head.

2415-12
Loosen the filter outlet fitting. Remove the inlet line.
Remove the filter outlet fitting and gaskets. Disconnect the injection pump inlet line.
NOTE: There are two gaskets on the filter outlet

fitting, one on each side of the fuel line.
Disconnect the nut on the injection pump inlet line.

2415-13
STEP 36
Disconnect the leak off line. Remove the fuel inlet fitting and gaskets
NOTE: There are two gaskets on the fuel inlet fit-

ting, one on each side of the fuel line.
Loosen the fuel inlet fitting on the filter head.
Disconnect the fuel line nut on the lift pump.
Revised 3-85 Printed in U.S.A.

2415-14
Remove the fuel line. Remove the fuel filter housing.
Remove the fuel filter inlet fitting.
Remove the nut that holds the fuel filter housing.

2415-15
STEP 45 STEP 48
~.
Remove the intake manifold cover.
STEP 46 STEP 49
Remove the valve covers. Remove the rocker arm bolts.
Remove intake manifold cover bolts. Remove the rocker arm assemblies.

2415-16
STEP 51 STEP 54
Remove the push rods from the cylinder head. Remove the cylinder head.
STEP 52 STEP 55
Remove the lift bracket bolts and the lift bracket. Remove the cylinder head gasket.
STEP 53 STEP 56
Remove the cylinder head bolts. Cover the cylinder bores and pistons. Clean all
foreign material from the cylinder head mounting
surface.
NOTE: The cylinders and pistons must be covered

to prevent damage to the pistons and cylinder
walls.
Rae 8-2607! Revised 3-85 Printed in U.S.A.

2415-17
Cylinder Head Disassembly
STEP 57
Put the cylinder head on a clean work surface. Remove the valve spring retainers.
Use a valve spring compressor to push down the Remove the valve springs.
valve springs.
Remove the valve seals.

Push down the valve springs and remove the valve
keepers.

2415-18
STEP 63 STEP 65
Check the cylinder head surface for warpage. Use

a straight edge and feeler gauge. Clean the ma-
IMPORTANT: Using paint, make a mark on the chined surface of the head. Use a heavy, accurate
valves, keepers and retainers. This will make sure straight edge to check for warpage at each side
the parts are installed in the original location. and between all cylinders. Also, check for end-to-
end warpage in six positions or more.
IMPORTANT: If the measurement is more than

0.762mm, the cylinder head must be machined or
replaced. Replace the cylinder head if the head
height is less than 93.80 mm, after the head is
machined.
Clean the cylinder head completely, removing car-

bon and other deposits. Check for cracks and any
sign of damage in the area of the fire ring contact.
Check the valve guides in three positions with a

bore gauge.

2415-19
STEP 67
Check the bore gauge with a micrometer.
NOTE: If the diameter is more than 8.089mm, a

valve guide must be installed.
Rae 8-260i1 Revised 3-85 Printed in U.S.A.

2415-20
EXPANSION PLUG REMOVAL AND INSTALLATION

Cylinder Head Installed
STEP 68 STEP 71
EDGE
EXPANSION PLUG
Remove the expansion plug from the cylinder

head.
Install the expansion plug into the cylinder head

until the top edge of the expansion plug is even
with the bottom edge of the chamfer .
.-11/l
Clean the sealing surface of all foreign material.
STEP 70
Apply Loctite 277 to the sealing surface of the

expansion plug.
Rae 8-26071 Rev1sed 3-85 Prmted in U SA

2415-21
Cylinder Head Disassembled

STEP 75
EDGE
EXPANSION PLUG

head.
Install the expansion plug into the cylinder head

with the bottom edge of the chamfer.

expansion plug.

2415-22
VALVE GUIDE REPLACEMENT
TOP OF VALVE GUIDE

CYLINDER HEAD SURFACE
\
Make a bushing 16.038 mm minimum diameteriD x
11.25 to 11.75 mm long. Install the bushing over the
valve guide. Push the valve guides into the cylinder
13.987 to 14.013 mm
head until the bushing makes contact with the cyl-
inder head surface.
Machine the bore to a diameter of 13.987 to 14.013

mm.
Valve Guide Installation Specifications:
Valve Guide Outside

Diameter ............... 14.026 to 14.038 mm
Diameter of Bore .......... 13.987 to 14.013 mm
Press Fit .................... 0.013 to 0.051 mm
Installed Height ............. 11.25 to 11.75 mm Ream the new valve guides to a diameter of 8.029
mm ± 0.010 mm with a reamer.

2415-23
INSPECTION OF THE VALVES AND VALVE SEATS
STEP 79 STEP 80 (Cont'd)
. ~FINE PITTING
t------..JUID]
"~
~
.. ..
•
·..
,A •.
.,
lfi/J!/J
Clean the valves with a power driven wire brush.
NOTE: THIS IS A NORMAL CONDITION.
Small amounts of very fine pitting can be found on

the surfaces of the valve face or seat after the
Do not scratch the valve stems. valves are cleaned. These are normal and will not
change the engine performance. This fine pitting is
caused by normal oxidation procedure and can
STEP 80 occur on any engine during the run-in period.
Check the valves for the following conditions.
t
VALVE STEM WITH A NARROW NECK
HEAVY CARBON AND VARNISH DEPOSITS
I 10
NOTE: REPLACE THE VALVE IF THIS CONDITION OC-

CURS.
This Condition Can be Caused by: NOTE: GRIND OR REPLACE THE VALVE IF THIS CONDI-
1. Valve does not have lubrication. TION OCCURS.
2. Restriction in the water passages.
3. Operating the engine under continued overload This condition is generally caused by worn valve
at too much engine RPM. guides or bad seals on the valves, permitting oil to
go by the valves. Low operating temperature is a
secondary cause. Worn piston rings and cylinder
walls will also permit too much oil to reach the
rGROOVE IN VALVE FACE combustion chamber.
RUST OR PITTING ON VALVE STEM
t-•"C +'';' r .s:;.t. . . o. ~- -' --· I[]
NOTE: GRIND OR REPLACE VALVE IF THIS CONDITION NOTE: REPLACE VALVE IF THIS CONDITION OCCURS.
OCCURS.
This condition can be caused by foreign material This condition can be caused by using bad quality
entering the engine through the intake system or engine oil or fuel and by not correctly keeping the
not giving service to the air intake system. engine in storage.

2415-24
STEP 80 (Cont'd) STEP 81
RUST OR PITTING IN VALVE FACE INTAKE VALVES
r 0]
NOTE: THIS CONDITION CAN BE CAUSED BY USING BAD

QUALITY ENGINE OIL OR FUEL.
DEEP BURNED VALVE FACE
Check the intake valve stem diameter at three

points along the stem. If the stem diameter is less
than 7.960 mm, the valve must be replaced.
CONCAVE VALVE HEAD

EXHAUST VALVES
NOTE: IF EITHER OF THESE CONDITIONS OCCUR, RE-
PLACE THE VALVES.
• - - - - 7 . 9 6 0 TO 7.980 mm
These conditions are generally caused by running
the engine at very high engine temperatures,
grinding the valve face too thin or valve grinding
that is not correct.
WORN RETAINER GROOVE 7.960 TO 7.980 mm
v Check the exhaust valve stem diameter at two

points as shown. If the stem diameter is less than
7.960 mm or the stem tip diameter is less than 7.960
mm, the valve must be replaced.
WORN STEM TIP
NOTE: IF EITHER OF THESE CONDITIONS OCCUR, RE-

PLACE THE VALVE.

2415-25
EXHAUST VALVE WITHOUT REPLACEABLE SEATS
1.52 mm MAX.
INTAKE VALVES WITHOUT REPLACEABLE SEATS
1.52 mm MAX.
Put the valves in the cylinder head and check to see

if the valve heads are recessed in the cylinder head.
If the valve head is recessed more than 1.52 mm
below the cylinder head surface, the valve must be
replaced or a valve insert must be installed to make
sure that there is equal compression ratios be-
tween cylinders.

2415-26
VALVE SEAT INSTALLATION
sreP sa
Machine the cylinder head to the following specifi- Clean the recessed area in the cylinder head. Put
cations for valve seats. the new valve seats in dry ice for a minimum of one
hour to shrink the valve seats for easy installation.
Exhaust Valve Seat Specifications: Use a driver and install the valve seats.
Diameter of Valve Seat .... 43.713 to 43.739 mm

Depth of Bore ............... 10.10 to 10.30 mm
A CAUTION: Always wear gloves to pre-
vent frostbite to your hands when han-
dling frozen parts.
Press Fit ..................... 0.05 to 0.092 mm
Intake Valve Seat Specifications:
Diameter of Valve Seat .... 47.063 to 47.089 mm

Depth of Bore ............... 10.30 to 10.50 mm
Press Fit ..................... 0.05 to 0.102 mm
Use a center punch and stake the valve seats in

three positions. Grind the valve seats to the correct
angle.

2415-27
REFACING INTAKE AND EXHAUST VALVES AND VALVE SEATS
STEP 86 STEP 87
VALVE AND SEAT GRINDING ANGLES
VALVE IDENTIFICATION 29DEGREE~~

ANGLE ~
The 45 degree exhaust valves are smaller in diame- 44 DEGREE ""'- ~

ter than the intake valves. ANGLE '\.._
\ '
B A
_+- · :~=======
The 30 degree intake valves are larger in diameter
than the exhaust valves.
45DEGR~~
ANGLE i:E ""'-
.. 30DEG~~
~
ANGLEiREE
\~~~,
---....,......-~..,....--
\~
45 DEGREE SEAT
~
30 DEGREE SEAT
If dimension A and B is less than 1.5 mm, the valve

must be replaced.
NOTE: Use a precision seat grinder. Take very

light cuts with the grinding stones so just enough
metal is removed, to end up with a good smooth
seat finish.

2415-28
STEP 90
30 DEGREE VALVES
45 DEGREE VALVES
Put a small amount of blue dye on the valve face.

Install the valve in the head and rotate the valve on
the seat.
Correct refacing of valves and seats will give a dye

pattern as shown.
NOTE: If the dye pattern is other than the patterns

shown, check the diagnosis of different dye pat-
terns on the following pages.
Remove the valve and look at the contact area on

the valve face and seat. The blue dye will be gone
from the valve face where the valve made contact
with the seat.

2415-29
DIAGNOSIS OF DIFFERENT DYE PATTERNS

45 Degree Exhaust valves
IF THE VALVE CONTACT AREA ON THE ......,.. USE A 45 DEGREE STONE TO LIFT AND ......,.. USE A 60 DEGREE STONE TO NARROW ......,.. CHECK THAT THE VALVE HEAD IS NOT ......,.. IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE WIDER, THE CONTACT AREA. THE LOWER CONTACT AREA, IN- RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
HAS BEEN GROUND). CREASED BY THE 45 DEGREE STONE. LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
SEAT CONTACT AREA ON THE VALVE

TOO LOW
~NTACTAREA IF THE VALVE CONTACT AREA ON THE

SEAT LOOKS LIKE THIS.
......,.. USE A 45 DEGREE STONE TO LIFT THE
CONTACT AREA.
......,.. USE A 60 DEGREE STONE TO LIFT AND
NARROW THE LOWER CONTACT AREA.
__...CHECK THAT THE VALVE HEAD IS NOT ....,...IF THE VALVE HEAD IS RE·
RECESSED MORE THAN 1.52 mm BELOW
THE CYLINDER HEAD SURFACE.
CESSED MORE THAN 1.52 mm,
REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
IF THE VALVE CONTACT AREA ON THE ......,.. USE A 45 DEGREE STONE TO LOWER , _ . USE A 30 DEGREE STONE TO NARROW __,. CHECK THAT THE VALVE HEAD IS NOT ....,...IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT AND TO MAKE WIDER, THE CONTACT THE UPPER CONTACT AREA, IN- RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
HAS BEEN GROUND). CREASED BY THE 45 DEGREE STONE. LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.

TOO HIGH
/ CONTACT AREA
IF THE VALVE CONTACT AREA ON THE
SEAT LOOKS LIKE THIS.
......,.. THE VALVE MUST BE REPLACED AND A
VALVE SEAT MUST BE INSTALLED BE-
CAUSE MORE GRINDING WILL NOT
CHANGE THE LOWER CONTACT POINT.

2415-30
IF THE VALVE CONTACT AREA ON THE ---+ USE A 45 DEGREE STONE TO INCREASE _....CHECK THAT THE VALVE HEAD IS NOT _.,. CHECKTHATTHEVALVE HEAD
SEAT LOOKS LIKE THIS (A SEAT THAT THE CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW IS NOT RECESSED MORE THAN
HAS BEEN GROUND.) THE CYLINDER HEAD SURFACE. 1.52 mm, REPLACE THE VALVE
-~~========
AND INSTALL A VALVE SEAT.

TOO NARROW
IF THE VALVE CONTACT AREA ON THE ---+THE VALVE MUST BE RE-

VALVE SEAT LOOKS LIKE THIS. PLACED AND A VALVE SEAT IN-
CONTACT AREA STALLED BECAUSE MORE
GRINDING WILL NOT CHANGE
THE LOWER CONTACT AREA.
IF THE VALVE CONTACT AREA ON THE ---+ USE A 30 DEGREE STONE TO LOWER _.... USE A 60 DEGREE STONE TO LIFT THE _.,.CHECK THAT THE VALVE HEAD IS NOT _.,.IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT THE UPPER CONTACT AREA. LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm,
LOW THE CYLINDER HEAD SURFACE.
w~::
t STALL A VALVE SEAT.
SEAT CONTACT AREA ON THE VALVE =========

TOO WIDE.
IF THE VALVE CONTACT AREA ON THE ---+USE A 30 DEGREE STONE TO LOWER _....USE A 60 DEGREE STONE TO LIFT THE _.,. CHECK THAT THE VALVE HEAD IS NOT _.,. IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS. THE UPPER CONTACT AREA. LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm,
CONTACT AREA THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.

2415-31
IF THE VALVE CONTACT AREA ON THE ....,.. USE A 30 DEGREE STONE TO MAKE ....,.. USE A 15 DEGREE STONE TO LOWER .....,.. CHECK THAT THE VALVE HEAD IS NOT .....,.. IF THE VALVE HEAD IS RE·
SEAT LOOKS LIKE THIS (A SEAT THAT WIDER AND TO LOWER THE CONTACT THE UPPER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm,
HAS BEEN GROUND). AREA. THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
""
STALL A VALVE SEAT.
SEAT CONTACT AREA ON THE

VALVE TOO HIGH
~, IF THE VALVE CONTACT AREA ON THE ....,.. THE VALVE MUST BE REPLACED AND A .....,.. IF THE VALVE HEAD IS RECESSED MORE
CONTACT AREA SEAT LOOKS LIKE THIS. VALVE SEAT INSTALLED BECAUSE THAN 1.52 mm, REPLACE THE VALVE
MORE GRINDING WILL NOT CHANGE AND INSTALL A VALVE SEAT.
"'-... THE LOWER CONTACT POINT.
1!-'
IF THE VALVE CONTACT AREA ON THE ....,.. USE A 30 DEGREE STONE TO MAKE ...,..CHECK THAT THE VALVE HEAD IS NOT
SEAT LOOKS LIKE THIS (A SEAT THAT WIDER THE CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW
HAS BEEN GROUND). THE CYLINDER HEAD SURFACE.
"'-...

TOO NARROW
~,
CONTACT AREA
IF THE VALVE CONTACT AREA ON THE ....,.. THE VALVE MUST BE REPLACED AND A
SEAT LOOKS LIKE THIS. VALVE SEAT INSTALLED BECAUSE
MORE GRINDING WILL NOT CHANGE
THE LOWER CONTACT POINT.

2415-32
THIS IS THE CORRECT SEAT CONTACT.,.. THE CORRECT EXHAUST VALVE CON- --+- 1 DEGREE INTERFERENCE ANGLE ...... CORRECT REFACING OF EXHAUST ....... IF THE VALVE HEAD IS RE-
AREA ON THE VALVE. TACT AREA ON THE SEAT WILL GIVE A VALVES AND VALVE SEATS WILL GIVE A CESSED MORE THAN 1.52 mm
SEAT WIDTH OF 1.47 TO 2.07 mm. 1 DEGREE INTERFERENCE ANGLE. THIS REPLACE THE VALVE AND IN-
ANGLE IS IMPORTANT BECAUSE THE STALL A VALVE SEAT.
ANGLE GIVES ASSISTANCE IN CUTTING
CARBON AND TO SEAT THE VALVES.
CONTACT AREA
30 DEGREE INTAKE VALVES ONLY

IF THE VALVE CONTACT AREA ON THE --+-USE A 30 DEGREE STONE TO LIFT AND __.. USE A 45 DEGREE OR 60 DEGREE STONE ...... CHECK THAT THE VALVE HEAD IS NOT ....... IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT TO MAKE WIDER THE CONTACT AREA. TO NARROW THE LOWER CONTACT RECESSED MORE THAN 1.52 mm, BE- CESSED MORE THAN 1.52 mm
HAS BEEN GROUND). AREA INCREASED BY THE 30 DEGREE LOW THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STONE. STALL A VALVE SEAT.

TOO LOW
IF THE VALVE CONTACT AREA ON THE --+- USE A 30 DEGREE STONE TO LIFT THE --+- USE A 45 DEGREE OR 60 DEGREE STONE ....... CHECK THAT THE VALVE HEAD IS NOT ....... IF THE VALVE HEAD IS RE-
~~ACT
SEAT LOOKS LIKE THIS. CONTACT AREA. TO NARROW THE LOWER CONTACT RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm,
AREA. THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
STALL A VALVE SEAT.
AREA

2415-33
IF THE VALVE CONTACT AREA ON THE _ , . USE A 15 DEGREE STONE TO LOWER _ , . USE A 45 DEGREE OR 60 DEGREE STONE __,..CHECK THAT THE VALVE HEAD IS NOT _,.IF THE VALVE HEAD IS RE-
SEAT LOOKS LIKE THIS (A SEAT THAT THE UPPER CONTACT AREA. TO LIFT THE LOWER CONTACT AREA. RECESSED MORE THAN 1.52 mm BELOW CESSED MORE THAN 1.52 mm
HAS BEEN GROUND) . THE CYLINDER HEAD SURFACE. REPLACE THE VALVE AND IN-
.......... STALL A VALVE SEAT.

TOO WIDE
'l, CONTACT AREA

IF THE VALVE CONTACT AREA ON THE
VALVE SEAT LOOKS LIKE THIS.
_,.USE A 15 DEGREE STONE TO LOWER
THE UPPER CONTACT AREA.
~USEA45DEGREEOR60DEGREESTONE
TO LIFT THE LOWER CONTACT AREA.
_,.CHECKTHATTHEVALVEHEADISNOT _,.IF THE VALVE HEAD IS RE-
RECESSED MORE THAN 1.52 mm, BE-
LOW THE CYLINDER HEAD SURFACE.
CESSED MORE THAN 1.52 mm,
'-....
STALL A VALVE SEAT.
1!-'
THIS IS THE CORRECT SEAT CONTACT THE CORRECT VALVE CONTACT AREA _ , . 1 DEGREE INTERFERENCE ANGLE --+- CORRECT REFACING OF THE INTAKE
AREA ON THE VALVE. ON THE SEAT WILL GIVE A SEAT WIDTH VALVE AND VALVE SEAT WILL GIVE A 1
OF 1.32 TO 1.92 mm. DEGREE INTERFERENCE ANGLE. THIS
'-.... ANGLE IS IMPORTANT BECAUSE IT
1!-'
GIVES ASSISTANCE IN CUTTING CAR-
BON AND TO SEAT THE VALVES.
CONTACT AREA --~
Rae 8-26071 Revised 3-85 Printed in U.S A.

2415-34
Cylinder Head Assembly

STEP 91 STEP 93
~~L...L..-TI\
Wl~~lll-1~-0-0
. .lo. . : . ~l l~::.:...,_~1
: :IJI_p
LETTER V
If you grind the valve seats, mark the cylinder head

•-
Apply lubrication to the valves. Install the valves in
the cylinder head.
with the letter "V".
STEP 94
STEP 92
lllldJ
Install new valve seals.
Mark the cylinder head with the letter "X" to indi- STEP 95
cate the following:
X - Oversize Bore
XX - Oversize Bore
0.25 mm machined from the cylinder head
or the cylinder block surface.
XXX- Oversize Bore
0.25 mm machined from the cylinder head
surface.
0.25 mm machined from the cylinder block
surface.
Check the valve springs with a valve spring tester.

The springs must have these specifications:
Free Length ......................... 55.63 mm

Outside Diameter ................... 33.81 mm
Wire Diameter ........................ 4.88 mm
Number of Coils .......................... 7.25
Compress to 49.25 mm .. 64to721b (285to321 N)

2415-35
STEP 96 STEP 99
Install the valve springs. Remove the spring compressor and hit the end of
the valve stems with a soft hammer to seat the valve
keepers.
STEP 97
Install the valve spring caps.
Clean the injector bores with a bore cleaner.
Push down the valve springs with a spring com-

pressor. Install the valve keepers.
NOTE: Always install new valve keepers when

new valves are installed.

2415-36
Rocker Arm Disassembly
STEP 101 STEP 104
Put the rocker arm assembly on a clean work sur- Remove the rocker arms.
face.
Use a micrometer and measure the rocker arm

Remove the snap rings. shaft for out of round. Measure three different lo-
cations around the shaft. If the rocker arm shaft is
less than 18.938 mm in diameter, the rocker arm
shaft assembly must be replaced.
STEP 106
Remove the washers.
Measure the rocker arm with a bore gauge in three

different locations around the bore.

2415-37
STEP 107
'
Use a micrometer to measure the bore gauge. If the
diameter of the bore is more than 19.05 mm, the
rocker arm must be replaced.

2415-38
Rocker Arm Assembly
I
ROCKER ARM SHAFT
STEP 108
Install the rocker arm on the rocker arm shaft with Install the snap rings in the groove on the rocker
the adjusting screws on the same end as the large arm shaft.
hole in the bracket.
Install the washers on the rocker arm shaft.

2415-39
Cylinder Head Installation
STEP
., 111
...,;,·:
STEP 113
Use the correct tap and clean all head bolt holes of Install the cylinder head.
foreign material.
STEP 114
Put a small amount of clean engine oil on the head

Install the correct head gasket:on the engine block, bolt threads.
see below.
&JO g:;o g:;o · ~~

0000000000000
000 0
£:;>o
0 0
~o
0 0 0
0 0 0 0 0
!
NOTCHES
Head Gasket Application

No Notches - Replacement Gasket
2 Notches- 0.25 mm oversize thickness Install the head bolts and washers. Tighten the
3 Notches- 0.50 mm oversize thickness bolts a small amount.
NOTE: Do not torque the head bolts at this time.

2415-40
STEP 116 STEP 119
Install the push rods in the cylinder head.
Tighten the cylinder head bolts to the correct tor-

que, following the torque sequence shown above.
Use the following steps to get the correct torque.
Step 1 -torque to 30 lb ft (41 Nm)(4.1 kgm)

Step 2 - torque to 60 lb ft (81 Nm)(8.1 kgm)
Step 3- torque to 93 lb ft (126 Nm)(12.6 kgm)
Install the rocker arm assembly.
STEP 120
STEP 118 '"'""t••·.
Tighten the rocker shaft bracket bolt to a torque of

Put a small amount of oil on the threads of the 18 lb ft (24 Nm)(2.4 kgm).
rocker arm head bolt.

2415-41
STEP 121 STEP 124

BOLT TORQUE SEQUENCE
Install a new intake manifold gasket.
~TEP 122
Install the intake manifold bolts and tighten to a

torque of 18 lb ft (24 Nm)(2.4 kgm}, following the
torque sequence shown in the inset.
STEP 125
Install the intake manifold.
STEP 123
Install the rear lift bracket.
Put loctite liquid teflon on the intake manifold

bolts.

2415-42
STEP 126 STEP 129 6-590 ENGINE
Install the rear lift bracket bolts and tighten to a Connect and tighten the leak off line.
torque of 57 lb ft (77 Nm)(7.7 kgm).
STEP 127 ST-590 AND STA-590 ENGINE
Install the injection pump inlet line.

Install the injection pump inlet tube.
STEP 128 ST-590 AND STA-590 ENGINE
Connect and tighten the inlet line.

Connect and tighten the inlet tube.

2415-43
STEP 135
Install the filter outlet fitting and gaskets. Install Install the filter inlet tube.
one gasket on each side of the tube.
STEP 136
STEP 133
Install a new o-ring on the filter housing and install

Tighten the fuel outlet fitting to a torque of 241b ft the filter housing.
(32 Nm)(3.2 kgm).
STEP 134
Install the filter housing nut and tighten to a torque

Install a new o-ring on the filter inlet tube. of 24 lb ft (32 Nm)(3.2 kgm).

2415-44
STEP 138 STEP 141
· Install the lift pump outlet tube. Connect and tighten the outlet tube to the lift
pump.
STEP 139
STEP 142
Install the filter housing inlet tube gaskets and

fitting. Install a gasket on each side of the tube. For correct fuel filter installation see the fuel filter
section.
STEP 140
Tighten the filter inlet fitting to a torque of 24 lb ft

(32 Nm)(3.2 kgm). Install the thermostat in the thermostat housing.
The pin in the thermostat must be at the top of the
thermostat housing.

2415-45
STEP 147
Install the bolts into the exhaust manifold. Install

the exhaust manifold gaskets on the bolts.
STEP 145
STEP 148
Install the front lift bracket.
Install the manifold on the cylinder head. Tighten

the bolts to a torque of 32 lb ft (43 Nm)(4.3 kgm),
follow the torque sequence shown above.
Install the thermostat housing assembly and bolts.

Tighten the bolts to c. rorque of 181b ft (24 Nm)(2.4
kgm).

2415-46
LOCATING TOP CENTER
While turning the engine with the turn over tool,

push the lock pin in. When the lock pin moves into
the camshaft gear the engine will be at top center.
Install the engine turn over tool into the flywheel

housing. Turn the engine over four revolutions to
make sure the push rods are seated correctly.

Rae 8-26071
2415-47
ADJUSTING THE ROCKER ARM TO VALVE CLEARANCE

Cold Setting
Check and adjust the intake and exhaust

the arrows show below.
FAN t
6 5 4 2 1
E E
...... .....
Number one cylinder top center compression
stroke
Valve Clearance, Cold: Intake Valves- 0.010 inch Install the engine turn over tool. Move the engine a
(0.254 mm) small amount in each direction. Pull the lock pin
Exhaust Valves - 0.020 inch out.
(0.508 mm)
Install the plug in the flywheel housing.

2415-48
STEP 155 STEP 157
Turn the engine one complete revolution. Tighten the injector nut to a torque of 41 to 441b ft
(55 to 60 Nm)(5.5 to 6.0 kgm).
Check and adjust the intake and exhaust valves as
the arrows show below.
STEP 158
FANt
6 5 4 3 2 1
E I I E I E
tJo tJro tjo ~o ~o1° 0
....................
I' Ill
o
D D ·
o
D
o
D ·
0 0 0 0 0
~
Number six cylinder top center compression

stroke
Valve Clearance, Cold: Intake Valves- 0.010 inch

(0.254 mm) Install the leak off line.
Exhaust Valves - 0.020 inch
(0.508 mm)
STEP 156
Install the leak off Ii ne fittings and gaskets. Tighten

the fitting to a torque of 4 lb ft (6 Nm)(0.6 kgm).
Put new seals on the injectors and install the injec-
tors.

2415-49
STEP 160 STEP 163
Remove the protective covers from the injection Install the alternator bracket and tighten the bolts
pump and injectors. Install the injector lines. to a torque of 18 lb ft (24 Nm)(2.4 kgm).
STEP 164
Connect and tighten the injector lines to the injec- Install the alternator and tighten the bolts.
tors and the injector pump.
STEP 165
STEP 162
Install the fan belt pulley bracket and tighten the

Install the bracket and tighten. bolts to a torque of 18 lb ft (24 Nm)(2.4 kgm).

2415-50
STEP 169
Install the belt tensioner bracket and tighten the Lift the belt tensioner and install the fan belt.
Allen head bolts to a torque of 18 lb ft (24 Nm)(2.4
kgm).
STEP 167
o install the turbocharger, see section 2465 in the

service manual.
Install the fan belt pulley and torque the bolts the
following:
STEP 171
Grade 8.8 bolts ............... 18 lb ft 24 Nm
(2.4 kgm) Start and operate the engine. Check the engine oil
Grade 10.9 ................... 25 lb ft 34 Nm pressure indicator to make sure of correct engine
(3.4 kgm) oil pressure. Check the rocker arms to make sure
that the arms are receiving oil.
Install the belt tensioner and tighten the bolt to a


2415-51
Install new gaskets on the valve covers. Install the valve cover bolts and tighten to a torque
of 18 lb ft (24 Nm)(2.4 kgm).
Install new o-rings on the valve cover bolts.

NOTE: The reserves the right to make improvements in
Section
2425
CYLINDER BLOCK
Crankshaft, Pistons, Rods, Sleeves, Camshaft,
Bearings, Seals and Flywheel
Written In Clear
And
Simple
English

October, 1984 (Revised March, 1985)
2425-2
TABLE OF CONTENTS
SPECIFICATIONS 4-5
SPECIAL TORQUES ............................................................................ 5-6
SPECIAL TOOLS .............................................................................. 7-10
SERVICING THE ENGINE BLOCK

Front Oil Seal Replacement ................................................................... 11-16
Rear Oil Seal Replacement ................................................................... 17-23
Front Oil Seal and Wear Sleeve Installation ................................................... 24-28
Rear Oil Seal and Wear Sleeve Installation .................................................... 28-35
Removal of Pistons and Rods ................................................................ 35-37
Cylinder Wall Inspection ...................................................................... 37-40
RECONDITIONING THE CYLINDER BLOCK

Reconditioning the Cylinder Block for Oversize Pistons ........................................... 41
Reconditioning the Cylinder Block for Sleeves ................................................ 42,43
Piston and Connecting Rod Disassembly and Inspection ....................................... 44-46
Piston Assembly ............................................................................ 47-51
REPLACEMENT OF MAIN BEARINGS WITHOUT REMOVING THE CRANKSHAFT

Removal .................................................................................... 51,52
Installation .................................................................................. 52,53
CRANKSHAFT AND MAIN BEARINGS

Removal .................................................................................... 54-61
Gear Removal .................................................................................. 61
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Gear Installation ............................................................................... 63
Installation ................................................................................. 64-72

2425-3
TABLE OF CONTENTS (Continued)

CAMSHAFT
Removal .................................................................................... 73-76
Bore Inspection ................................................................................ 77
Bushing Removal and Installation ............................................................ 77,79
Valve Lifter Inspection ....................................................................... 79,80
Disassembly and Inspection .................................................................. 80,81
Gear Installation ............................................................................ 81,82
Installation ................................................................................. 82-87
FLYWHEEL
Removal ....................................................................................... 87
Ring Gear Removal and Installation ............................................................. 88
Installation .................................................................................... 88

60 mm Expansion Plug, Camshaft ............................................................... 89
58 mm Expansion Plugs ........................................................................ 90
26 mm Expansion Plugs ........................................................................ 91
22.5 mm Expansion Plug ........................................................................ 92
18 mm Expansion Plugs ..................................................................... 93,94
10 mm Expansion Plugs ..................................................................... 94,95
CRANKCASE PRESSURE CHECK (BLOW BY)

Manometer Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Testing ........................................................................................ 97
Manometer Removal ........................................................................... 98

2425-4
SPECIFICATIONS
CYLINDER BLOCK
ID of Cylinder ................................................................. 102.00 to 102.04 mm
Maximum Cylinder Out of Round ......................................................... 0.038 mm
Maximum Cylinder Taper ................................................................ 0.076 mm
Machine Cylinder Block Bore to .............................................. 102.40 to 102.44 mm
Machine Cylinder Block Bore to .............................................. 102.90 to 102.94 mm
CYLINDER SLEEVE
Machine Cylinder Block Bore to ............................................. 104.485 to 104.515 mm
Machine Cylinder Sleeve Bore to ............................................... 101.90 to 101.94 mm
HONING SPECIFICATIONS (Finished Diameter)
Standard Cylinder Bore ....................................................... 102.00 to 102.10 mm
0.5 mm Oversize Bore ......................................................... 102.50 to 102.54 mm
1.0 mm Oversize Bore ......................................................... 103.00 to 103.04 mm
Cylinder Sleeve Bore .......................................................... 102.00 to 102.04 mm
PISTON
OD 12 mm From the Bottom, 90 Degrees from Piston Pin ...................... 101.873 to 101.887 mm
ID of Piston Pin Bore .......................................................... 40.006 to 40.012 mm
PISTONS RINGS
No. 1 Compression
End Gap in 102.02 ID Cylinder .................................................... 0.25 to 0.55 mm
Maximum Service Limit .............................................................. 0.806 mm
Side Clearance ................................................................ 0.075 to 0.120 mm
No. 2 Compression
End Gap in 102.02 ID Cylinder ...................................................... 0.25 to 0.55 mm
Side Clearance ................................................................ 0.075 to 0.120 mm
No. 3 Oil Control Ring
End Gap in 102.02 ID Cylinder .................................................... 0.25 to 0.55 mm
Protrusion Above Cylinder Block (Maximum) ............................................. 0.660 mm
PISTON PIN
OD of Pin ..................................................................... 39.997 to 40.003 mm
CONNECTING ROD
Bushing ID Installed ........................................................... 40.053 to 40.067 mm
Journal ID Without Bearing Liners ............................................. 72.987 to 73.013 mm
Bearing Oil Clearance ........................................................... 0.038 to 0.116 mm

2425-5
SPECIFICATIONS (Continued)
CRANKSHAFT
Crankshaft End Clearance ....................................................... 0.137 to 0.264 mm
Center Main Bearing Thrust Surface Thickness ............................................. 2.50 mm
Connecting Rod Journal Standard OD .......................................... 68.987 to 69.013 mm
0.25 mm OD Undersize, Grind to ............................................. 68.737 to 68.763 mm
100 mm OD Undersize, Grind to .............................................. 67.987 to 68.013 mm
Connecting Rod Journal Maximum Taper ................................................. 0.013 mm
Connecting Rod Journal Out of Round Maximum ............. ~ .......................... 0.050 mm
Main Bearing Oil Clearance ...................................................... 0.041 to 0.119 mm
Main Bearing Journal Standard OD ............................................ 82.987 to 83.013 mm
Main Bearing Journal Bore ID No Liners ........................................ 87.982 to 88.018 mm
CAMSHAFT
ID of Bushing Installed .........................................-............... 54.107 to 54.133 mm
ID of Camshaft Bore .......................................................... 54.1 07 to 54.133 mm
Maximum Service Limit ...................................... ~ ........................ 54.146 mm
OD of Each Camshaft Bearing Surface ......................................... 53.987 to 54.013 mm
Camshaft Thrust Clearance ........................................................ 9.42 to 9.58 mm
GEAR TRAIN BACKLASH
Crankshaft Gear to Camshaft Gear ................................................. 0.08 to 0.33 mm
Maximum Service Limit (All Gears) ...................................................... 0.45 mm
SPECIAL TORQUES
Belt Tensioner Bolt .............................................. 32 lb ft 43 Nm
(4.3 kgm)
Camshaft Plate Bolts ............................................ 18 lb ft 24 Nm

(2.4 kgm)
Connecting Rod Bolts ........................................... 74 lb ft 100 Nm

(10.0 kgm)
Crankshaft Pulley Bolts ......................................... 101 lb ft 137 Nm

(13.7 kgm)
Fan Pulley Bracket Bolts ......................................... 181b ft 24 Nm

(2.4 kgm)

2425-6
SPECIAL TORQUES (Continued)

Fan Pulley Bolts, Grade 8.8 ...................................... 18 lb ft 24 Nm
(4.3 kgm)
Fan Pulley Bolts, Grade 10.9 ..................................... 25 lb ft 34 Nm

(3.4 kgm)
Flywheel Bolts ..................................... , ........... 101 lb ft 137 Nm

(13.7 kgm)
Flywheel Housing Bolts .......................................... 45 lb ft 60 Nm

(6.0 kgm)
Fuel Inlet Nut ................................................... 24 lb ft 32 Nm

(3.2 kgm)
Injection Pump Nut .............................................. 48 lb ft 65 Nm

(6.5 kgm)
Injection Pump Lock Bolt ........................................ 22 lb ft 30 Nm

(3.0 kgm)
Injection Pump Mounting Nuts ................................... 18 lb ft 24 Nm

(2.4 kgm)
Injection Pump Bracket Bolts .................................... 18 lb ft 24 Nm

(2.4 kgm)
Front Cover Bolts ............................................... 18 lb ft 24 Nm

(2.4 kgm)
Front Housing Bolts ............................................. 18 lb ft 24 Nm

(2.4 kgm)

(12.6 kgm)
Main Bearing Bolts ............................................. 129 lb ft 175Nm

(17.5 kgm)
Oil Suction Tube Bolts .......................................... 18 lb ft 24 Nm

(2.4 kgm)
Seal Carrier Bolts ................................................ 7 lb ft 9 Nm

(0.9 kgm)
Starter Retaining Bolts .......................................... 32 lb ft 43 Nm

(4.3 kgm)
Fuel Inlet Bolts .................................................. 24 lb ft 32 Nm

(3.2 kgm)
Fuel Outlet Bolt ................................................. 24 lb ft 32 Nm

(3.2 kgm)

2425-7
SPECIAL TOOLS
Crankshaft Seals and Wear Sleeve
fJ? INSTALLATION TOOL
IN SEAL KIT)
PROTECTIVE
SLEEVE
~
w
I
WEAR SLEEVE INSTALLATION TOOL
PROTECTIVE SLEEVE (INCLUDED IN KIT)
REAR SEAL KIT FRONT SEAL KIT
~: !J,©rt:TITE
I .
TORQUE WRENCH LB FT
504 GASKET ELIMINATOR t~~·.:. .-~~ .

B17428 50 ml TUBE ~·"' 'l' :-.
.\!., ...,.~~
B17504 300 ml CARTRIDGE
SAFETY SOLVENT
M20863 12 OZ AEROSOL
277 PLASTIC GASKET
B17427 50 ml BOTTLE
Cylinder Block and Cylinder
CAS-1690 ENGINE TURN OVER TOOL
CAS-1358 RIDGE REAMER CAS-10056M OUTSIDE MICROMETER
CAS-10064M 504 GASKET ELIMINATOR

0 TO 150 mm DEPTH MICROMETER B17428 50 ml TUBE CAS-10063M INSIDE MICROMETER
817504 300 ml CARTRIDGE

2425-8
SPECIAL TOOLS (Continued)

Cylinder Block and Cylinder (Continued)
FEELER GAUGE (METRIC)
CYLINDER HONE
80 TO 150 GRIT STONE
250 TO 300 GRIT STONE
Pistons, Connecting Rods, Connecting Rod Bearings and Main Bearings
CAS-10063M INSIDE MICROMETER -
TORQUE WRENCH LB FT
CAS-10133 BEARING OVEN/HEATER
CAS-10066-1A DIAL INDICATOR CAS-10056M OUTSIDE MICROMETER
Flywheel
... .... :.:
,
504 GASKET ELIMINATOR

B17428 50 ml TUBE
TORQUE WRENCH LB FT

2425-9

Camshaft
CAS-10063M INSIDE MICROMETER
CAS-10133 BEARING OVEN/HEATER

CAS-10066-1A DIAL INDICATOR
CAS-10056M OUTSIDE MICROMETER
CAS-1691 GEAR PULLER
TORQUE WRENCH LB FT
CAS-1412 CAM BEARING SERVICE KIT
Crankcase Pressure Check (Blow By)
CAS-1692 MANOMETER
0.221 INCH ORIFICE 4 CYLINDER
0.302 INCH ORIFICE 6 CYLINDER
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2425-10
Expansion Plugs
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"SNAP-ON" A157B

2425-11
SERVICING THE ENGINE BLOCK

Front Oil Seal Replacement
Case 6T-590 Engine. Make sure the upper and lower mark on the crank-
shaft pulley are in align. If the mark is not in align
the crankshaft pulley must be replaced.
Case 6TA-590 Engine.
• Loosen the fan pulley bolts .
Case 6-590 Engine.

2425-12
STEP 4
Lift the belt tensioner and remove the fan belt. Remove the bolts from the crankshaft pulley.
Remove the fan pulley bolts and remove the fan Remove the crankshaft pulley.
pulley.

2425-13
STEP 11
Remove the front cover bolts and remove the front Remove the seal from the front cover.
cover.
Clean the seal surface with loctite safety solvent.

Clean the mounting surfaces of all foreign materi-
al.
STEP 10
Clean the crankshaft seal surface with loctite safe-

ty solvent.
IMPORTANT: The seal surface on the crankshaft

must be free of all oil and grease to prevent dam-
age to the oil seal.

2425-14
STEP 13 STEP 16
Install two guide bolts (M8 x 1.25 x 75 mm). Install the front cover bolts. Do not tighten the
bolts.
STEP 14
STEP 17
Install a new front cover gasket.

Install the seal installation tool into the front cover
with the small diameter toward the engine. This
STEP 15 will center the front cover with the crankshaft.
STEP 18
Install the front cover. ·
Tighten the front cover bolts to a torque of 18 lb ft

(24 Nm)(2.4 kgm).

2425-15
STEP19 STEP 22
Remove the installation tool. Remove the protective sleeve.
STEP 20 STEP 23
Put loctite 277 on the outside surface of the seal. Install the installation tool and push the seal to the
correct depth. The seal will be at the correct depth
when the outside diameter of the installation tool
STEP 21 makes contact with the front cover.
STEP 24
Carefully install the protective sleeve and seal on

the crankshaft. Push the seal on the crankshaft
until the seal makes contact with the seal surface.
Remove the seal installation tool.

2425-16
STEP 25 STEP 28
Install the crankshaft pulley. Lift the belt tensioner and install the fan belt.
STEP 26 STEP 29
Install the crankshaft pulley bolts. Tighten the Tighten the fan pulley bolts as follows:
bolts to a torque of 101 lb ft (137 Nm)(13.7 kgm). Grade 8.8 ............. 18 lb ft 24 Nm (2.4 kgm)
Grade 10.9 ............ 25 lb ft 34 Nm (3.4 kgm)
STEP 27
Install the fan pulley and bolts.

2425-17
Rear Oil Seal Replacement

STEP 30 STEP 33
Remove the engine oil pan. See Section 2445 for oil Remove the bolts from the flywheel.
pan removal.
STEP 34
STEP 31
Remove the flywheel from the flywheel housing.

Remove the bolts that hold the starter to the fly-
wheel housing.
STEP 35
STEP 32
Connect a chain and a hoist to the flywheel hous-

ing.
Remove the starter from the flywheel housing.

2425-18
STEP 36 STEP 39
Remove two bolts from the flywheel housing and Remove the two guide bolts.
install two guide bolts.
STEP 40
STEP 37
Clean the flywheel housing and the engine block

Remove the remainder of the bolts from the fly- mounting surfaces of all foreign material.
wheel housing.
STEP 41
STEP 38
Remove the a-ring from the seal carrier.

Remove the flywheel housing from the engine
block.

2425-19
STEP 42 STEP 45
Remove the bolts from the seal carrier. Remove the seal from the seal carrier.
STEP 43 STEP 46
Remove the seal carrier from the crankshaft. Clean the seal surface with loctite safety solvent.
STEP 44 STEP 47
Clean the mounting surfaces of all foreign materi- Clean the seal surface on the crankshaft with loc-
al. tite safety solvent.
IMPORTANT: The crankshaft sealing surface

must be free of all oil and grease to prevent dam-
age to the oil seal.

2425-20
STEP 48 STEP 51
Install two guide bolts (M6 x 1.00 x 50 mm). Install the seal carrier bolts and remove the guide
bolts. Do not tighten the seal carrier bolts.
STEP 49
STEP 52
Install a new seal carrier gasket.

Install the seal installation tool into the seal carrier
with the small diameter toward the engine. This
STEP 50 will center the seal carrier to the crankshaft.
STEP 53
Install the seal carrier.
Tighten the seal carrier bolts to a torque of 71b ft (9

Nm)(0.9 kgm).

2425-21
STEP 54 STEP 57
Remove the seal installation tool. Install the seal installation tool with the small diam-
eter toward the seal.
STEP 55
STEP 58
Install the seal and protective sleeve over the

crankshaft until the outside diameter of the seal Push the seal into the seal carrier until the outside
makes contact with the seal carrier. diameter of the seal installation tool makes contact
with the seal carrier.
STEP 56
STEP 59
Remove the protective sleeve.

Remove the seal installation tool.

2425-22
STEP 60 STEP 63
Install a new a-ring on the rear seal carrier. Install the flywheel housing.
STEP 61 STEP 64
Apply Loctite 504 to the sealing surface of the Install the flywheel housing bolts and remove the
engine block. guide bolts.
STEP 62 STEP 65
Install two guide bolts in the engine block. Install the flywheel housing bolts and tighten the
bolts to a torque of 45 lb ft (60 Nm)(6.0 kgm).

Rae 8-26081
2425-23
STEP 66 STEP 69
Remove the hoist and the lift chain from the fly- Install the starter into the flywheel housing.
wheel housing.
STEP 70
STEP 67
Install the starter retaining bolts and tighten the

Install the flywheel on the crankshaft. bolts to a torque of 32 lb ft (43 Nm)(4.3 kgm).
STEP 68 STEP 71
Install the flywheel retaining bolts and tighten the Install the engine oil pan. See Section 2445 for oil
bolts to a torque of 101 lb ft (137 Nm)(13.7 kgm). pan installation.

2425-24
Front Oil Seal, Seal and Wear Sleeve Installation

Used when crankshaft flange is worn and standard seal does not stop oil flow.
STEP 72 STEP 75
Make sure the upper and lower mark on the crank- Remove the fan pulley bolts and the fan pulley.
shaft pulley are in align. If the mark is not in align
the crankshaft pulley must be replaced.
STEP 76
STEP 73
Remove the crankshaft pulley bolts and the crank-

shaft pulley.
Loosen the fan pulley bolts.

2425-25
STEP 78 STEP 81
Remove the front cover. Clean the seal surface with loctite safety solvent.
STEP 79 STEP 82
Clean the front cover mounting surfaces of all for- Put loctite 277 on the outside diameter of the seal
eign material. surface and install the seal in the front cover.
STEP 80 STEP 83
Remove the oil seal from the front cover. Put the seal installation tool on the oil seal. The
small diameter of the seal installation tool must be
toward the seal.

2425-26
STEP 84 STEP 87
Push the seal into the cover until the outside diam- Install the wear sleeve installation tool over the
eter of the installation tool makes contact with the wear sleeve. Push the wear sleeve on the crank-
cover. shaft until the flange makes contact with the face
of the crankshaft gear.
STEP 85
STEP 88
Clean the crankshaft with loctite safety solvent.

Remove the wear sleeve installation tool.
NOTE: The seal surface must be free of all oil and
grease to prevent damage to the oil seal.
STEP 89
STEP 86
Install two guide bolts (M8 x 12.5 x 75 mm).
Install the wear sleeve on the crankshaft with the

flange toward the engine.

2425-27
STEP 90 STEP 93
Install a new front cover gasket. Install the crankshaft pulley.
STEP 91 STEP 94
Carefully install the front cover. Install the crankshaft pulley bolts and tighten the
bolts to a torque of 101 lb ft (137 Nm)(13.7 kgm).
STEP 92
STEP 95
Install the front cover bolts and tighten the bolts to

a torque of 18 lb ft (24 Nm)(2.4 kgm). Install the fan pulley and the fan pulley bolts.

2425-28
STEP 96 STEP 97
Lift the belt tensioner and install the fan belt. Tighten the fan pulley bolts as follows:
Grade 8.8 ............. 18 lb ft 24 Nm (2.4 kgm)
Grade 10.9 ............ 25 lb ft 34 Nm (3.4 kgm)
Rear Oil Seal and Wear Sleeve Installation

Used when the crankshaft flange is worn and standard seal does not stop oil flow.
STEP 98 STEP 100
Remove the engine oil pan. See Section 2445 in the Remove the starter from the flywheel housing.
service manual for oil pan removal.
STEP 101
STEP 99
Remove the bolts from the flywheel.

Remove the bolts that hold the starter to the fly-
wheel housing.

2425-29
STEP 102 STEP 105
Remove the flywheel from the flywheel housing. Remove the remader of the flywheel housing bolts.
STEP 103 STEP 106
Install a lift chain and a hoist to the flywheel hous- Remove the flywheel housing.
ing.
STEP 107
STEP 104
Remove the guide bolts.

Install two guide bolts.

2425-30
STEP 108 STEP 111
Clean the surface of the flywheel housing and the Remove the seal carrier from the crankshaft.
engine block of all foreign material.
STEP 112
STEP 109
Clean the gasket surface on the seal carrier and the

Remove the a-ring from the seal carrier. engine block of all foreign material.
STEP 110 STEP 113
Remove the bolts from the seal carrier. Remove the seal from the seal carrier.

2425-31
STEP 114 STEP 117
Clean the seal surface with loctite safety solvent. Clean the crankshaft seal surface with loctite safe-
ty solvent.
STEP 115
STEP 118
Install the seal in the seal carrier.

Put the wear sleeve on the crankshaft with the
flange toward the engine.
STEP 116
STEP 119
Install the seal installation tool. Push the seal into

the seal carrier until the outside diameter of the
seal installation tool makes contact with the seal Install the wear sleeve installation tool on the wear
carrier. sleeve.

2425-32
STEP 120 STEP 123
Push the wear sleeve on the crankshaft until the Install two guide bolts (M6 x 1.00 x 50 mm).
flange of the wear sleeve is even with the rear seal
surface on the crankshaft.
STEP 124
IMPORTANT: The wear sleeve flange must be
even with the rear seal surface of the crankshaft.
STEP 121
Install a new seal carrier gasket.
STEP 125
Remove the wear sleeve installation tool.
STEP 122
Carefully install the seal carrier.
Clean the seal surface with loctite safety solvent.
IMPORTANT: The crankshaft seal surface must

be free of all oil and grease to prevent damage to
the seal.
2425-33
STEP 126 STEP 129
Install the seal carrier bolts and tighten the bolts to Install two guide bolts in the engine block.
a torque of 7 lb ft (9 Nm)(0.9 kgm).
STEP 130
STEP 127
Install the flywheel housing.

Install a new o-ring on the seal carrier.
STEP 131
STEP 128
Install the flywheel housing bolts and remove the

Apply loctite 504 to the sealing surface on the guide bolts.
engine block.

2425-34
STEP 132 STEP 135
Disconnect the hoist and remove the lift chain. Install the flywheel bolts and tighten to a torque of
101 lb ft (137 Nm)(13.7 kgm).
STEP 133
STEP 136
Tighten the bolts to a torque of 45 lb ft (60 Nm)(6.0

kgm). Install the starter in the flywheel housing.
STEP 134 STEP 137
Install the flywheel on the crankshaft. Install the starter bolts and tighten the bolts to a

2425-35
STEP 138
Install the engine oil pan. See Section 2445 in the

service manual for oil pan installation.
Removal of Pistons and Rods

STEP 139 STEP 141
Remove the manifolds and cylinder head from the Check the side clearance of the piston connecting
engine. See Section 2415 of the service manual for rods. Replace the connecting rods if the side clear-
removal. ance is more than 0.330 mm.
STEP 140 STEP 142
~RIDGE~
Remove the engine oil pan and inlet tube. See Remove the carbon from the top of the cylinder
Section 2445 of the service manual for removal. walls. Check the cylinder walls for a ridge at the top
of the ring movement zone. A ridge will cause dam-
age to the piston when the piston is removed. A
ridge will have to be removed with a ridge reamer.
2425-36
STEP 143 STEP 146
Install a ridge reamer into the cylinder. Put a identification mark on each piston for assem-
bly.
STEP 144
STEP 147
Remove the ridge from the cylinder walls.

Remove the rod cap bolts.
STEP 145
STEP 148
Put a mark on each rod cap for cylinder identifica-

tion. Remove the rod cap.

2425-37
STEP 149
Remove the pistons from the top of the engine

block.
Cylinder Wall Inspection
STEP 150
Inspect the cylinder walls for the following condi-
tions.
Normal Wear Worn Cylinder Wall
A smooth surface with some of the cross-hatch A smooth surface between the upper and lower
pattern showing between the upper and lower lim- limits of the ring movement area shows a worn
its of the ring movement area shows normal wear. cylinder wall. See Step 151 and 152 to measure the
There will always be a small amount of wear pre- cylinder bore for out-of-round and taper.
sent because of combustion pressure moving the
top ring against the cylinder wall.
Normal wear shows acceptable cylinder wall con-

ditions. See Step 151 and 152 to measure the cylin-
der bore for tapes and out-of-round.

2425-38
Scoring on Cylinder Walls Dusted Cylinder
Too much area in the piston ring movement area

shows a dusting failure.
A dusting failure will cause the following:

1. Lower area of piston wall will show wear.
2. Too much piston ring groove wear.
3. Too much piston ring side clearance.
4. Washed away areas of the piston ring lands
where the aluminum will be gone.
5. Piston rings will have too much face contact and
wear which can be seen as a reduction in radial
width and increase in end gap.
6. Chrome piston rings will show wear through the
face. The chrome will be worn off the face and
base iron can be seen.
Scoring on cylinder walls is caused by metal mov- 7. The cylinder heads can have smooth intake
ing from one location to a different location. This is ports and worn valve guides.
shown by heavy vertical lines. The vertical lines are
caused by metal coming in contact with the piston. All of these conditions are caused by dirt which is
The scoring can be in one specific area or it can mixed with the intake air.
occur the complete length of the piston movement.
If this condition is present, the cylinder must be
machined and the piston and rings replaced.

2425-39
STEP 151 STEP 152
Measure the cylinder wall bore for taper as follows:

1. Measure the bore parallel to the crankshaft at the
top end of the ring travel zone.
2. Measure the bore in the same position at the
bottom end of the ring travel zone.
3. Measure the bore at right angles to the crank-
shaft at the top end of the ring travel zone.
bottom end of the travel zone.
Compare the results of the measurements (1) and

(3) with (2) and (4), to find out if the bore has taper.
To measure use a inside micrometer, bore gauge
or taper gauge. If the taper is more than 0.076 mm,
bore the cylinder. Measure the cylinder wall bores for out-of-round
as follows:
1. Measure the bore parallel to the crankshaft at the
top end of the ring travel.
bottom end of the ring travel.
3. Measure the bore at right angles to the crank-
shaft at the top end of the ring travel.
bottom end of the ring travel.
Compare the measurements (1land (3) to find the

out-of-round wear at the top end of the bore.
Compare the measurements (2) and (4) to find the

out-of-round wear at the bottom of the bore.
If out-of-round is more than 0.038 mm, bore the

cylinders.
STEP 153
IMPORTANT: Before removing glaze, cover the
crankshaft journals with a clean cloth to prevent
abrasives and dirt caused by the cylinder hone
from falling on the crankshaft.

2425-40
STEP 154 STEP 155
If new rings are used, the glaze must be removed Use a 3/8 inch or1/2 inch drill to power the cylinder
from the cylinder bore so that the piston rings can hone. Use a lubricant/coolant with the hone to
correctly seat against the cylinder wall during the keep the hone and the stones free of foreign mate-
run-in time. rial.
Start the hone at the top of the cylinder bore and
Removing glaze can be done by usin~ a cylinder
actuate the hone up and down until the correct
hone with 250 to 300 grit stone.
cross-hatch pattern is reached. The correct cross-
hatch pattern is 40 to 60 degrees from horizontal.
Too much glaze (smooth surface) on cylinder
walls of a new engine or an engine with an overhaul Use a 80 to 150 grit stone to reach the correct
is caused by run-in procedure that is not correct. cross-hatch pattern.
Use a 250 to 300 grit stone to reach the correct
Glaze does not permit the piston rings to seat cor- cylinder bore finish.
rectly in the cylinder sleeves. This will cause too
much oil consumption.
STEP 156
Too much glaze on the cylinder walls can be pre-
vented by giving your customer instructions in the
correct run-in procedure. See Section 1024 in the
service manual for the correct run-in procedure.
After removing the glaze, clean the cylinder walls

f.
with a clean cloth, warm water and a mild deter-
gent soap. After cleaning the cylinder walls, clean
the cylinder walls again with clean engine oil.
NOTE: Clean the cylinder walls until a clean white
cloth keeps completely clean, one cleaning opera-
tion is not enough.
IMPORTANT: Do not use gasoline, diesel fuel or
kerosene to clean cylinders because these materi-
als will not remove the abrasives from the sleeve
surface.
Rae 8-26081 Ro"io:orl ~-85 Printed in U.S.A.
2425-41
RECONDITIONING THE CYLINDER BLOCK

Reconditioning the Cylinder Block for Oversize Pistons
NOTE: Many of the photographs in this section
show a cylinder block that has been cut in half for STEP 159
photo graphic purposes.
STEP 157
Machine the cylinder bore to a diameter of 103.00

to 103.04 mm for the 1.0 mm oversize pistons. See
Step 160 for the correct procedure to hone the
The cylinder block must be disassembled before cylinder bore.
the cylinder can be machined for oversize pistons.
STEP 160
STEP 158
Use a 3/8 or 1/2 inch drill to power the hone. Use a

Machine the cylinder bore to a diameter of 102.50 lubricant/coolant with the hone to keep the hone
to 102.59 for the 0.5 mm oversize pistons. See Step and the stones free from foreign material.
160 for the correct procedure to hone the cylinder
bore. Start the hone at the top of the cylinder bore and

cross-hatch pattern.

cylinder bore finish.

2425-42
Reconditioning the Cylinder Block for Sleeves

STEP 161 STEP 164
The cylinder block must be disassembled before Freeze the cylinder sleeves and push the cylinder
the cylinder block can be machined for sleeves. sleeves in the bore until the sleeve makes contact
with the ridge at the bottom of the cylinder bore.
STEP 162 NOTE: You must freeze the cylinder sleeves be-
fore installation.
CAUTION: Always wear gloves to pre-

h vent frostbite to your hands when han-
. . d/ing frozen parts.
STEP 165
Measure 6.35 mm up from the bottom of the cylin-

der bore. Put a mark on the cylinder at the 6.35 mm
measurement.
STEP 163
If the cylinder sleeve is not even with the cylinder

block surface, the sleeve must be machined.
NOTE: The cylinder sleeve must be even with the

cylinder block.
Machine the cylinder bore to the measured depth

in Step 162 to a diameter of 104.500 to 104.515 mm.
IMPORTANT: Do not bore the cylinder beyond

the measured depth.

2425-43
STEP 166
Measure the diameter of the piston sleeve with a Use a 3/8 inch or 1/2 inch drill to power the hone.
bore gauge. Use a lubricant/coolant with the hone to keep the
bore and the stone free from foreign material.
STEP 167 Start the hone at the top of the cylinder bore and

cross-hatch pattern.

cylinder bore finish.
Measure the bore gauge with a micrometer. The

cylinder diameter must be machined to a diameter
of 102.00 to 102.04 mm.

2425-44
Piston and Connecting Rod Disassembly and Inspection

STEP 169 STEP 172
Put the piston assembly on a clean work surface. Remove the connecting rod.
STEP 170 STEP 173
Remove the piston pin retaining ring. Remove the first and second compression rings.
STEP 171 STEP 174
Remove the piston pin from the piston. Remove the oil ring.
NOTE: The oil ring is a two piece ring.

2425-45
STEP 175 STEP 177
Measure the piston pin bore. If the piston pin bore

is more than 40.025 mm the piston must be re-
placed.
STEP 178
Measure the inside diameter of the connecting rod

for wear and out-of-round. If the inside diameter is
more than 40.092 mm the connecting rod must be
replaced.
Measure the diameter of the piston across the

STEP 176 thrust face 12 m m from the bottom of the piston, at
right angles to the piston pin holes. Replace the
piston if the diameter is less than 101.823 mm.
STEP 179
Measure the diameter of the piston pin. If the diam-

eter is less than 39.990 mm the piston pin must be
replaced.
Break an old piston ring in half and use the broken

ring half to clean the piston ring grooves. Too
much deposit in the ring grooves can force the
rings out and will cause scoring.

2425-46
STEP 180 STEP 182
Check the side clearance of the oil ring in the Clean the piston holes with a small drill or fine wire.
piston. Insert a feeler gauge between the upper
surface of a new ring and the piston lands to check
the clearance. Replace the piston if side clearance
is more than 0.13 mm.
STEP 181
Check the side clearance of the second compres-

sion ring. Replace the piston if the side clearance is
more than 0.15 mm.

2425-47
Piston Assembly
STEP 186
Put the piston rings in the cylinder and check end Install the first compression ring on the piston. The
gap. Replace the piston rings if the end gap is more piston ring must be installed with the side marked
than 0.806 mm. TOP toward the top of the piston to give good oil
control.
NOTE: The top piston ring on the 6T-590 and 6TA-

590 engine is a key stone type ring.
STEP 187
Install the oil ring. Install the spring first and the oil
ring second.
The first compression ring, in a replacement set of
NOTE: The spring must be between the oil ring rings, must have a special lap design on the sur-
and the piston. face that contacts the cylinder wall.
STEP 185 STEP 188
Install the second compression ring. The piston Rotate the piston rings so that the ring ends are
ring must be installed with the side marked TOP separated by 120 degrees.
toward the top of the piston to give good oil con-
trol.

2425-48
STEP 189 STEP 192
Install the connecting rod in the piston. The num- Apply lubrication to the pistons, piston rings and
ber on the connecting rod must be opposite of the cylinder walls, using clean engine oil.
number on the piston.
NOTE: Install the pistons in the correct bore.
STEP 190 STEP 193
Install the piston pin. Install a ring compressor on the piston and careful-
ly install the piston in the cylinder.
STEP 191 IMPORTANT: Make sure that the arrow on top of

the piston is toward the front of the engine.
STEP 194
Install the piston pin retaining rings.
Measure the connecting rod journals on the crank-

shaft. Measure the front and rear of each journal,
checking for taper. If the taper is more than 0.013
mm, reconditioning of the journals must be done.

2425-49
STEP 195 STEP 197
The connecting rod journals must be checked Clean the connecting rod journals and the rod
again, 90 degrees from the first measurements for bearing liners. Put a piece of plastigage on the
out-of-round. If out-of-round is more than 0.050 bearing cap journal or the journal on the crank-
mm, reconditioning of the journals must be done. shaft.
STEP 196 STEP 198
Install the liners. The liner locks must be in align- Install the bearing caps.
ment.
NOTE: Make sure that the number on the bearing
NOTE: When installing the liners, make sure that cap is the same as the number on the connecting
the liner locks are in alignment. Use a sliding type rod.
movement when installing the liners. Never push
on the center of the liner locks.

2425-50
STEP 199 STEP 201
Lubricate the connecting rod bolts with clean en- Apply lubrication to the bearing liners before in-
gine oil and torque the bolts. See below. stallation, using clean engine oil.
Torque Sequence:
Step 1 - Torque to 37 lb ft (50 Nm)(5.0 kgm) STEP 202
Step 2- Torque to 74 lb ft (100 Nm)(10.0 kgm)
STEP 200
Lubricate the connecting rod bolts with clean en-

gine oil and torque the bolts. See below.
Torque Sequence:
Remove the bearing caps and check the clearance. Step 1 - Torque to 37 lb ft (50 Nm)(5.0 kgm)
The clearance must be between 0.038 mm to 0.129 Step 2- Torque to 74 lb ft (100 Nm)(10.0 kgm)
mm. If the clearance is more than 0.129 mm, under-
size bearing liners must be installed and recondi-
tioning of the bearing journals must be done by STEP 203
grinding.
NOTE: A clearance of 0.038 mm to 0.116 mm is

required when installing new bearing liners.
Install the engine oil inlet tube. See Section 2445 of

the service manual for the inlet tube and the oil pan
installation.

2425-51
STEP 204 STEP 205
Use a dial indicator to check piston protrusion. Install the cylinder head and manifold. See Section
The piston protrustion must not be more than 2415 of the service manual. ·
0.660 mm above the cylinder block.
REPLACEMENT OF THE MAIN BEARINGS

WITHOUT REMOVING THE CRANKSHAFT
Removal
STEP 206 STEP 208
Remove the engine oil pan and gasket. See Section Remove the bolts from the main bearing cap.
2445 of the service manual.
NOTE: Remove only one cap at a time to prevent
the crankshaft from moving.
STEP 207
STEP 209
Remove the bolts from the oil inlet tube. See Sec-
tion 2445 of the service manual for the oil inlet tube
removal. Remove the main bearing cap.

2425-52
STEP 210
To remove the front main bearing liner, use a thin

piece of plastic to push the bearing liner out.
Installation
STEP 211 STEP 213
Put a new bearing liner in the bearing cap.

Put a new bearing liner on the crankshaft. Use a
thin piece of plastic to push the bearing liner in NOTE: Make sure the bearing liner locks are al-
position. igned when installing the liners. Slide the liner in
position. Never push on the center of the liners.
STEP 212 STEP 214
Install the bearing cap and torque the mounting

Put a piece of plastigage on the crankshaft journal. bolts. See below.
Torque Sequence:
Step 1 - Torque to 43 lb ft (58 Nm)(5.8 kgm)

2425-53
STEP 215 STEP 217
Remove the bearing cap and check the clearance. Add lubrication to the cap bolts. Install the cap
Clearance must be 0.041 to 0.140 mm. New liners bolts and torque. See below.
must be installed if the clearance is more than
0.140 mm. Torque Sequence:
NOTE: The crankshaft must be machined if the Step 2- Torque to 86 lb ft (116 Nm)(11.6 kgm)
clearance is more than 0. 119 mm with the new Step 3- Torque to 129 lb ft (175 Nm)(17.5 kgm)
liners.
STEP 218
STEP 216
Install a new oil inlet tube gasket. See Section 2445

Add lubrication to the bearing liners and install the of the service manual for the installation of the oil
bearing cap. inlet tube.
STEP 219
Install the oil pan. See Section 2445 of the service

manual.
2425-54
CRANKSHAFT AND MAIN BEARINGS

Removal
Remove the cylinder head. See Section 2415 of the Remove the oil pan. See Section 2445 in the service
service manual for cylinder head removal. manual for oil pan removal.
Make sure the upper and lower mark on the crank- Remove the oil inlet tube bolts. See Section 2445
shaft pulley are in align. If the mark is not in align for the oil inlet tube removal.
replace the crankshaft pulley.
STEP 222
Remove the front cover bolts.

shaft pulley.

2425-55
Remove the front cover.
Loosen the injection pump lock bolt and remove

the slotted tab washer.
Turn the engine over with a engine turn over tool

and push the lock into the camshaft gear. Tighten the injection pump lock bolt to a torque of
22 lb ft (30 Nm)(3.0 kgm).

Rae 8-26081
2425-56
STEP 232
Loosen the pump shaft lock bolt and move the slot Remove the lifter cover bolts.
washer off the lock bolt shoulder. Tighten the lock
bolt to a torque of 22 lb ft (30 Nm)(3.0 kgm).
STEP 233
NOTE: The slot washer will be loose after the lock ·
bolt has been torqued.
STEP 231
Remove the lifter cover.
STEP 234
Remove the injection pump and primer pump. See

Section 3412 in the service manual.
Remove the breather cover.

2425-57
STEP 235 STEP 237
Clean the lifter cover mounting surfaces of all for- Remove the bolts that hold the camshaft thrust
eign material. plate.
STEP 236 STEP 238
Install pins to hold the lifters in place. Remove the camshaft thrust plate.

2425-58
STEP 239 STEP 241
Remove the camshaft. Remove the front housing.
STEP 242
Remove the front housing bolts. Clean all mounting surfaces of foreign material.

2425-59
STEP 243 STEP 246
Remove the bolts that hold the starter to the fly- Remove the bolts from the seal carrier.
wheel housing.
STEP 247
Remove the seal carrier.

Remove the starter.
STEP 248
Clean the seal carrier mounting surfaces of all for-

See Steps 101 through 108 to remove the flywheel eign material.
and flywheel housing.

2425-60
STEP 249 STEP 252
Remove the bolts from the connecting rod bearing Remove the bolts from the crankshaft main bear-
caps. ing caps.
STEP 253
FLYWHEEL
Remove the connecting rod bearing caps. FAN
Each bearing cap has a number for assembly iden-

tification.
STEP 254
Remove the pistons and connecting rods.
Remove the crankshaft main bearing caps.

2425-61
STEP 255
Remove the crankshaft from the engine. Clean the oil spray nozzle with a small wire. If the
nozzle is damaged it must be replaced.
Remove the main bearing liners from the engine.

Remove the oil spray nozzle from the bearing car-
rier.
Crankshaft Gear Removal

STEP 259 STEP 260
Pull the gear off the crankshaft. Remove the pin from the crankshaft if the pin has
been damaged.

2425-62
Crankshaft Inspection
Measure the main bearing journals to see if the Measure the connecting rod journals for taper.
journals are worn. Measure the front and rear of Measure the front and rear of each journal. Grind
each journal. If the diameter is less t.han 82.962 the journals if the taper is more than 0.013 mm.
mm, grind the crankshaft journals.
NOTE: Grind the crankshaft journals undersize STEP 264

0.25 mm, 0.50 mm, 0.75 mm or 1.00 mm, if the
crankshaft journals are worn more than 0.025 mm.
STEP 262
Check the connecting rod journals again, 90 de-

grees from the first measurements (Step 263) for
out of round. Grind the journals if out of round is
more than 0.050 mm.
Measure the main bearing journals, again, 90 de-

grees from the first measurements (Step 261) for
out of round. If the out of round is more than 0.050
mm, grind the journals and use undersize liners.

2425-63
Crankshaft Gear Installation
STEP 265
Heat the crankshaft gear for a minimum of 25 min Install the heated gear on the crankshaft.
utes at 250° F (121 o C). Use a bearing heater oven.
STEP 266
Install the crankshaft gear pin. The pin must be

0.040 inch (1.02 mm) above the crankshaft surface.

2425-64
Crankshaft Installation
......
Install the oil spray nozzle into the bearing carrier. Install the crankshaft in the engine block.
Install the liners in the bearing caps. Make sure the

Install the bearing liners. liner locks are aligned. Use a sliding type move-
ment when installing the liners. Never push on the
center of the liners.
STEP 273
Add lubrication to the bearing liners. Use clean

engine oil.
Clean the main bearing journals and put a piece of
plastigage on the journals to check main bearing
oil clearance.

2425-65
STEP 274
FAN Check the main bearing oil clearance. Clearance

Make sure the number on main bearing cap is in must be 0.041 to 0.140 mm. If the clearance is more
the correct number sequence. than 0.140 mm, undersize bearing liners must be
installed. Install new undersize liners which will
STEP 275 give a clearance of 0.041 to 0.119 mm.
NOTE: If the clearance is more than 0.140 mm, the

crankshaft must be machined.
Install the main bearing cap bolts and tighten to a

Add lubrication to the liner. Use clean engine oil.
Remove the main bearing caps.

2425-66
STEP 281
Add lubrication to the cap bolts. Install the cap Install a new front housing gasket.
bolts and torque. See below.
Torque Sequence: STEP 282

Install the front housing.
Install the front housing bolts and tighten to a

Put a dial indicator on the crankshaft gear. Check torque of 18 lb ft (24 Nm)(2.4 kgm).
the crankshaft end clearance. The end clearance
must be 0.137 to 0.264 mm. If the clearance is more
than 0.332 mm, after all the main bearing liners
have been replaced, the crankshaft must be re-
placed.
NOTE: To get an accurate reading, use a pry bar
between the crankshaft and the number two and
number four main bearing caps as shown above.

2425-67
Add lubrication to the camshaft bearing journals. Install the thrust plate bolts and tighten to a torque
Use clean engine oil. of 18 lb ft (24 Nm)(2.4 kgm).
Make sure the timing marks on the crankshaft and Put a dial indicator on the camshaft gear. Check
camshaft are aligned. the backlash between the camshaft gear and the
crankshaft gear. Backlash must be 0.08 to 0.33
mm. If backlash is more than 0.33 mm, the gears
must be replaced.
NOTE: Too much backlash can also be caused by

a worn camshaft bushing.
Install the camshaft thrust plate behind the cam-

shaft gear.
Remove the pins from the lifters.

Rae 8-26081
2425-68
Install two guide bolts and the breather cover. Install the lifter cover.
Remove the protective cover from the gasket. Install new seals on the lifter cover bolts.
Install a new gasket on the lifter cover. Install the lifter cover bolts and tighten to a torque
of 9 lb ft (12 Nm)(1.2 kgm).

2425-69
STEP 296
Install the injection pump and the hand primer Install the bearing liners on the connecting rods
pump. See Section 3412 in the service manual. and rod caps.
IMPORTANT: Make sure the liner locks are al-

STEP 297 igned when installing the liners. Use a sliding type
movement when installing the liners. Never push
on the center of the liners.
Add lubrication to the cylinder walls and piston

rings. Use clean engine oil.
NOTE: To remove the glaze from the cylinder

walls do Step 154 through Step 156.
Clean the connecting rod journals and the bearing
liners. Put a piece of plastigage on the rod cap liner
or the rod journals.
Install the ring compressor on the piston and care-

fully push the piston down into the cylinder.
IMPORTANT: Make sure that the word FRONT is

toward the front of the engine. Make sure the cor-
rect connecting rod is in the correct cylinder.

2425-70
STEP 301 STEP 303
Install the bearing caps. Remove the bearing caps and check the clearance.
The clearance must be 0.023 to 0.089 mm. If the
NOTE: Make sure the number on the bearing cap clearance is more than 0.114 mm, undersize bear-
is equal to the number on the connecting rod. ing liners must be installed and reconditioning of
the bearing journals must be done. Install new
bearing liners which will give a clearance of 0.023
STEP 302 to 0.089 mm.
STEP 304
Torque the connecting rods. See below.
Step 1 -Torque to 37 lb ft (50 Nm)(S.O kgm)

Step 2- Torque to 74 lb ft (100 Nm)(10.0 kgm) Add lubrication to the bearing liners. Use clean
engine oil.

2425-71
STEP 305 STEP 308
Add lubrication to the rod bolts. Install the rod Clean the rear crankshaft seal surface of all foreign
bolts and torque. See below. material, using loctite safety solvent. See seal in-
stallation in this section for installing the rear
Step 1 - Torque to 37 lb ft (50 Nm)(5.0 kgm) crankshaft seal and the flywheel housing.
STEP 309
STEP 306
Install the flywheel and tighten the retaining bolts

Install the cylinder head. See Section 2415 for in- to a torque of 101 lb ft (137 Nm)(13.7 kgm).
stalling the cylinder head.
STEP 310
STEP 307
Install a new oil inlet tube gasket. See Section 2445

Clean the front crankshaft seal surface of all for- for oil inlet tube installation.
eign material, using loctite safety solvent. See seal
installation in this section for installing the front
crankshaft seal and the crankshaft pulley.

2425-72
Install the engine oil pan. See Section 2445 for oil
pan installation.

2425-73
CAMSHAFT
Removal
STEP 312 STEP 315
Make sure the upper and lower mark on the crank- Remove the fan pulley bolts and the fan pulley.
shaft pulley are in align. If the upper and lower
mark are not in align, replace the crankshaft pul-
ley. STEP 316
STEP 313

shaft pulley.
Loosen the fan pulley bolts.

STEP 317
STEP 314
Remove the front cover bolts.
Lift the belt tensioner and remove the fan belt.

2425-74
STEP 318
Remove the front cover. Disconnect the fuel lines and remove the primer
pump. See Section 3412 in the service manual.
Clean the front cover and the housing surface of all

foreign material. Remove the bolts from the valve covers.
STEP 320
Disconnect the fuel lines and remove the injection Remove the valve covers.
pump. See Section 3412 in the service manual.

2425-75
STEP 324 STEP 327
Remove the bolts from the rocker arm assemblies. Remove the bolts from the lifter cover.
STEP 325 STEP 328
Remove the rocker arm assemblies. Remove the lifter cover.
STEP 326 STEP 329
Remove the push rods. Remove the breather cover.

2425-76
STEP 330 STEP 333
Clean the lifter cover and the cylinder block of all Remove the camshaft thrust plate.
foreign material.
STEP 331
Remove the camshaft from the engine block.

Raise the lifters and install retaining pins to hold
the lifters in place, when the camshaft is removed.
STEP 332
Remove the bolts from the camshaft thrust plate.

2425-77
Camshaft Bushing Removal and Installation

STEP 335 STEP 337
Remove the engine oil pan. See Section 2445 in the If the bushing diameter is more than 54.146 mm,
service manual. the front camshaft bushing must be replaced.
STEP 336 STEP 338
Measure the camshaft bores. Use a bore gauge. If the intermediate or the rear bores are more than
The bores must be measured in two positions. 54.146 mm, disassemble the engine block and line
Take a second measurement 90 degrees from the bore the bores. See Section 1024 in the service
first measurement. manual for machining dimensions.

2425-78
STEP 339 STEP 342
Remove the front housing bolts. Put a bushing puller in the engine block and pull
the bushing out of the cylinder block.
STEP 340
STEP 343
Remove the front housing.

Install the bushing on the puller. Align the oil
holes. Pull the bushing into the cylinder block until
STEP 341 it is even with the housing.
STEP 344
Clean the front housing and cylinder block surface

of all foreign material.
Install two guide bolts.

2425-79
STEP 345
Install a new gasket. Install the front housing bolts and tighten to a
Install the front housing.
Valve Lifter Inspection
STEP 348 STEP 349
Remove the retaining pins from the lifters and re- Measure the lifter bores. Use an expandable bore
move the lifters. gauge.

2425-80
STEP 350 STEP 352
If the diameter of the lifter bore is more than 16.055 Put clean engine oil on the lifters before installa-
mm the engine block must be replaced. tion.
STEP 351 STEP 353
Measure the outside diameter of the valve lifter Install the lifters in the cylinder block and fasten in
stem. Replace the valve lifters if the outside diame- position with retaining pins.
ter of the lifter stem is less than 15.936 mm.
Camshaft Disassembly and Inspection
STEP 354 STEP 355
Press the gear off the camshaft. Remove the shaft key.

2425-81
STEP 356 STEP 357
Measure the front and rear of each bearing surface Each bearing surface must be measured in four
on the camshaft. Use a micrometer. positions. Measure the front and rear bearing sur-
faces again, 90 degrees from the first measure-
ment.
NOTE: Replace the camshaft if the outside diame-

ter of any bearing surface is less than 53.962 mm.
Camshaft Gear Installation

STEP 358 STEP 359
Install the shaft key. Heat the camshaft gear a minimum of45 minutes at
a temperature of 250°F (121°C). Use a bearing
heater oven.

2425-82
STEP 360
Install the camshaft gear on the camshaft with the

lock pin hole down.
Camshaft Installation
STEP 361 STEP 363
Lubricate the camshaft bearing surface with clean Install the camshaft thrust plate.
engine oil.
STEP 362
Install the camshaft thrust plate bolts and tighten

Align the timing marks on the camshaft with the to a torque of 18 lb ft (24 Nm)(2.4 kgm).
timing mark on the crankshaft.

2425-83
STEP 367
Check the camshaft end clearance with a dial indi- Remove the retaining pins from the lifters.
cator. The end clearance must not be more than
0.130 to 0.470 mm. If the clearance is more than
0.470 mm the camshaft thrust plate must be re- STEP 368
placed.
STEP 366
Install two guide bolts and install the oil breather

cover.
Put a dial indicator on the camshaft gear and check STEP 369
the gear clearance between the camshaft gear and
the crankshaft gear. Gear clearance must be 0.08
to 0.33 mm. The gears must be replaced if the
clearance is more than 0.45 mm.
NOTE: Too much gear clearance can also be

caused by worn camshaft bushings.
Remove the protective cover from the lifter gasket.

2425-84
STEP 373
Install a new gasket on the lifter cover. Install the lifter cover bolts and tighten to a torque
of 9 lb ft (12 Nm)(1.2 kgm).
STEP 374
Install the lifter cover.

Install a new injection pump housing gasket.
STEP 372
STEP 375
Install new seals on the lifter cover bolts.

Install the injection pump on the front housing.
See Section 3412 in the service manual for injec-
tion pump installation.

2425-85
STEP 376 STEP 379
Install the primer pump. See Section 3412 in the Install the push rods.
service manual for primer pump installation.
STEP 380
STEP 377
Install the rocker arm assemblies.
Clean the crankshaft seal surface with loctite safe-

ty solvent. See front seal installation in this section. STEP 381
STEP 378
Install the head bolts that hold the rocker arm as-
sembly and tighten the bolts to a torque of 93 lb ft
(126 Nm)(12.6 kgm).
If the engine oil pan was removed, see Section
2445 in the service manual for installation.

2425-86
STEP 385
Install the rocker arm bracket bolts. Tighten the See Section 3412 in the service manual to install
bracket bolts to a torque of 18 lb ft (24 Nm)(2.4 the injection pump fuel lines.
kgm).
STEP 386
STEP 383
See Section 2465 in the service manual to install

Adjust the valve clearance. See Section 2415 for the turbocharger.
adjusting the rocker arm to valve clearance.
STEP 384
Install the valve covers and tighten the bolts to a


Rae 8-26081
2425-87
STEP 387 STEP 389
Install the fan pulley and bolts. Tighten the fan pulley bolts as follows:
Grade 8.8 ............. 18 lb ft 24 Nm (2.4 kgm)
Grade 10.9 ............ 25 lb ft 34 Nm (3.4 kgm)
Lift the belt tensioner and install the fan belt.
FLYWHEEL
Removal
STEP 390 STEP 391
Remove the bolts from the flywheel. Remove the flywheel from the flywheel housing.

2425-88
Ring Gear Removal and Installation

STEP 392 STEP 394
Remove the ring gear from the flywheel, using a Install the flywheel. Tighten the retaining bolts to a
drift and hammer. Work around the circumference torque of 101 lb ft (137 Nm)(13.7 kgm).
of the ring gear.
STEP 393
Heat the new ring gear, 400° to 450° F (204° to

232°C), in oil or in an oven. Do not use a torch to
heat the ring gear.
Install the ring gear on the flywheel.

2425-89

60 mm Expansion Plug, Camshaft
NOTE: The flywheel and flywheel housing must be

removed to replace the camshaft expansion plug.
STEP 395
Remove the expansion plug from the cylinder Apply Loctite 277 to the sealing surface of the
block. expansion plug.
STEP 398
Use Loctite safety solvent to clean the sealing sur- Install the expansion plug into the cylinder block.
face of all foreign material. Hit the expansion plug in the center to lock the
expansion plug in position.

2425-90
58 mm Expansion Plugs
STEP 399 STEP 402
EDGE
EXPANSION PLUG ---+-1----
CHAMFER

block.
Clean the sealing surface of all foreign material. Install the expansion plug into the cylinder block,
STEP 401

expansion plug.

2425-91
STEP 406
EXPANSION PLUG--++--
CHAMFER

block.
h
Install the expansion plug into the cylinder block
STEP 405 with the bottom edge of the chamfer.

expansion plug.

2425-92
22.5 mm Expansion Plug

STEP 407 STEP 410
EDGE CHAMFER
EXPANSION PLUG

block.
STEP 408
Install the expansion plug into the bore, until the

top edge of the expansion plug is even with the
bottom edge of the chamfer.
Clean the expansion plug bore of all foreign mate-

rial, use Loctite safety solvent.

expansion plug.

2425-93
18 mm Expansion Plug
STEP 414
Put a small amount of grease in the expansion Use Loctite safety solvent to clean the sealing sur-
plug. face of all foreign material.
STEP 412 STEP 415
Drill a small hole in the center of the expansion Apply Loctite 277 to the sealing surface of the
plug. expansion plug.
STEP 413
Install a screw in the expansion plug and remove

the expansion plug from the cylinder block.

2425-94
STEP 416
EDGE CHAMFER
EXPANSION PLUG

STEP 417 STEP 418
Put a small amount of grease in the expansion Drill a small hole in the center of the expansion
plug. plug.

2425-95
STEP 419 STEP 421
Install a screw in the expansion plug and pull the Apply Loctite 277 to the sealing surface of the
expansion plug out of the cylinder block. expansion plug.
STEP 420 STEP 422

CHAMFER
EDGE
EXPANSION PLUG
Use Loctite safety solvent to clean the sealing sur-

face of all foreign material.

until the top edge of the expansion plug is even to
the bottom edge of the chamfer.

2425-96
CRANKCASE PRESSURE CHECK (BLOW BY)

Manometer Installation
STEP 423 STEP 426
Loosen the clamp and remove the breather hose. Turn each connector on the manometer one turn
counterclockwise.
STEP 424
Install the breather adapter with the six cylinder

orifice. Connect the tube from the breather adapter to one
of the connectors on the manometer.
NOTE: Use the 0.302 inch for six cylinder engines.
STEP 428
STEP 425
Push the button on the gauge and move the gauge

Install the manometer. up or down, until the zero on the gauge and the
liquid in the tube are aligned.

2425-97
Testing
NOTE: Do the following Steps to get the correct MANOMETER READING
manometer readings. Inches of
Water Lim in
Step 1 - Warm the engine to operating tempera-
ture.
1 59
Step 2 - Operate the engine at the rated speed. 2 84
3 103
Step 3 - Use the hydraulics to apply a load to the 4 119
engine during the manometer test.
5 133
6 145
STEP 429 7 155
8 164
9 172
10 180
11 187
12 193
13 200
14 206
15 211
16 217
Take a manometer reading from the engine. Add CRANKCASE PRESSURE

the number of lowered inches to the number of (BLOW BY) LIMITS
raised inches for the correct manometer reading.
See example below. Engine Engine L/min Lim in
LOWERED INCHES+ 1.5
Model Speed Maximum New Worn Limit
RAISED INCHES 1.5
TOTAL 3.0 INCHES 6-590 2100 38.0 76.0

2200 40.0 80.0
See the chart for manometer reading and 2600 45.0 90.0
crankcase pressure (Blow By) limits.
6T-590 2100 59.0 118.0
2200 61.0 122.0
6TA-590 2100 84.0 168.0

2200 87.0 174.0

2425-98
Manometer Removai
STEP 430 STEP 433
Disconnect the tube from tl1e connector. Remove the adapter from the breather tube.
STEP 431
Turn each connector on the manometer one turn Install breather hose and tighten the clamp.
clockwise.
STEP 432
Remove the manometer.
NOTE: The CASE coRPORATION reserves the right to make improvements in


Section
2445
LUBRICATION SYSTEM
Oil Pan, Oil Pump, Oil Cooler and Oil Filter Housing
Written In Clear
And
Simple
English
Rae 8-26091 Printed in U.S.A.

CASE CORPORATION October. 1984 (Revised March, 1985)
2445-2
TABLE OF CONTENTS
SPECIAL TOOLS ................................................................................. 2
SPECIFICATIONS ................................................................................ 3
SPECIAL TORQUES .............................................................................. 3
SERVICING THE LUBRICATION SYSTEM

Oil Pump Removal ............................................................................. 4,5
Disassembly, Inspection and Assembly ........................................................... 6
Oil Pump Installation .......................................................................... 7,8
OIL PRESSURE RELIEF VALVE

Relief Valve Disassembly ........................................................................ 9
Relief Valve Assembly .......................................................................... 10
OIL FILTER HOUSING AND OIL COOLER

Oil Filter Housing and Oil Cooler Removal .................................................... 11,12
Oil Cooler and Filter Housing Installation ..................................................... 12,13
OIL PAN AND OIL INLET TUBE

Oil Pan Removal ............................................................................... 14
Oil Inlet Tube Removal ...................................................................... 14,15
Oil Inlet Tube Installation ....................................................................... 15
Oil Pan Installation ............................................................................. 16
SPECIAL TOOLS
.....
,,...:..
"~..:,.
~~:·~~.
~"!\:'~·
~ ....
,~'!!,
SAFETY SOLVENT- M20863 12 OZ AEROSOL
CAS-10066A DIAL INDICATOR
CAS-1357 VALVE SPRING TESTER

2445-3
SPECIFICATIONS
Engine Oil Capacity:
Total Capacity With Oil Filter ................................... 16 qts 15.0 L
Total Capacity Without Oil Filter ................................ 15 qts 14.3 L
Change Engine Oil and Oil Filters Every 250 Hours
Engine Oil Specifications:

20W-40 Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30° F
15W-40 Above . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1oo F
10W-30 Below .................................................. 90°F
Oil Pump Idler Gear to Crankshaft .......................................................... 0.450 mm

Oil Pump Rotor Clearance ................................................................. 0.178 mm
Oil Pump Relief Valve Spring Specifications:
Number of Coils ............................................................................... 17
Free Length ............................................................................. 55.83 mm
Outside Diameter ....................................................................... 14.02 mm
Wire Diameter ............................................................................ 2.03 mm
Assembled Height:
Compress to 44.98 mm ................................................................ 63 to 79 N
Spring Load Height:
Compress to 39.98 mm ............................................................... 95 to 113 N
SPECIAL TORQUES
Oil Pump Mounting Bolts ........................................ 181b ft 24 Nm
(2.4 kgm)
Front Cover Bolts ............................................... 18.1b ft 24 Nm

(2.4 kgm)
Crankshaft Pulley Bolts ......................................... 101 lb ft 137 Nm

(13.7 kgm)
Fan Pulley Bracket Bolts ......................................... 18 lb ft 24 Nm

(2.4 kgm)
Fan Pulley Bolts (Grade 8.8) ..................................... 18 lb ft 24 Nm

(2.4 kgm)

(3.4 kgm)
Filter Head Bolts ................................................ 18 lb ft 24 Nm

(2.4 kgm)
Oil Inlet Tube Bolts .............................................. 18 lb ft 24Nm

(2.4 kgm)
Oil Pan Bolts .................................................... 18 lb ft 24 Nm

(2.4 kgm)
Oil Pan Drain Plug .............................................. 55 lb f t 75 Nm

(7.5 kgm)
Relief Valve Plug ................................................ 90 lb ft 120 Nm

(12.0 kgm)
2445-4
SERVICING THE LUBRICATION SYSTEM

Oil Pump Removal
STEP 1 STEP 2
Case 6T-590 engine. Loosen the fan pulley bolts.
Case 6TA-590 engine.
Lift the belt tensioner pulley and remove the fan

belt.
STEP 4
Remove the bolts and the fan belt pulley.

2445-5
STEP 5
Remove the bolts from the crankshaft pulley.
STEP 6
Remove the crankshaft pulley.
STEP 10
Remove the front cover bolts. Remove the oil pump.

2445-6
Disassembly, Inspection and Assembly
STEP 11 STEP13
Put the oil pump on a clean work surface. Measure the clearance between the lobe on the
gear and lobe on the pump body. If the clearance is
more than 0.178 mm the pump must be replaced.
STEP12
STEP 14
Remove the back cover plate.
Install the back cover plate on the oil pump.

2445-7
Oil Pump Installation
STEP 15 STEP 17
Install the oil pump in the engine block. Check the backlash between the oil pump idler
gear and the crankshaft. Put a dial indicator on the
oil pump idler gear. If the backlash is more than
STEP 16 0.450 mm the oil pump must be replaced.
STEP 18
Install the oil pump bolts and tighten to a torque of

18 lb ft (24 Nm)(2.4 kgm). Follow the torque se-
quence above.
Clean the seal surface on the crankshaft with loc-
NOTE: To prevent damage to the oil pump do not tite safety solvent. See Section 2425 in the service
tighten the bolts more than 18 lb ft (24 Nm)(2.4 manual for front cover installation.
kgm). There will be a small clearance between the
oil pump flange and the cylinder block.
STEP 19
Install the crankshaft pulley.

2445-8
STEP 20 STEP 22
Install the crankshaft pulley bolts and tighten to a Lift the fan belt tensioner pulley and install the fan
torque of 101 lb ft (137 Nm}(13.7 kgm). belt.
STEP 21 STEP 23
Install the fan pulley and the bolts. Torque the fan pulley bolts as follows:
Grade 8.8 ............. 18 lb ft 24 Nm (2.4 kgm)
Grade 10.9 ............ 25 lb ft 34 Nm (3.4 kgm)

2445-9
OIL PRESSURE RELIEF VALVE

Disassembly
STEP 24 STEP 26
Remove the relief valve plug. Remove the relief valve.
STEP 25 STEP 27
Remove the relief valve spring. Remove the gasket from the relief valve plug.

2445-10
Relief Valve Assembly

STEP 30
STEP 28
Install the relief valve spring.
STEP 31
Install the relief valve.
STEP 29
Install a new gasket on the relief valve plug.
STEP 32
Check the relief valve spring for the following

specifications:
Free Length ......................... 55.83 mm Tighten the relief valve plug to torque of 90 lb ft
Wire Diameter ........................ 2.03 mm (120 Nm)(12.0 kgm).
Outside Diameter ................... 14.02 mm
Number of Coils ........................... 17
Assembled Height:
Compress to 44.98 mm ............ 63 to 79 N
Spring Load Height:
Compress to 39.98 mm ........... 95 to 113 N
2445-11
OIL FILTER HOUSING AND OIL COOLER

Removal
STEP 33
Remove the oil filter. Remove the filter head bolts.
STEP 34 ST-590 and STA-590 Engine STEP 37
Remove the oil filter head.
STEP 35 ST-590 and STA-590 Engine STEP 38
Remove the fitting from the oil filter head. Remove the oil cooler.

2445-12
STEP 39 STEP 40
Clean all surfaces of foreign material. ead on a clean work surface and
remove the cold oil relief valve.
Oil Cooler and Filter Housing Installation

STEP 41 STEP 43
Install the cold oil relief valve in the oil filter head.
STEP 44
Install the oil cooler.

2445-13
STEP 45 STEP 48 6T-590 and 6TA-590 Engine
Install a new filter head gasket. Install and tighten the fitting in the filter head.
STEP 46
Install the oil filter head. Connect and tighten the turbocharger pressure
tube.
STEP 47
STEP 50
Install the oil filter head bolts and tighten to a

torque of 18 lb ft (24 Nm)(2.4 kgm). See the operators manual for servicing the oil filter.

2445-14
OIL PAN AND OIL INLET TUBE

Oil Pan Removal
STEP 51 STEP 53
Remove the oil pan drain plug and remove the oil. Remove the oil pan.
STEP 52 STEP 54
Remove the oil pan bolts and washers. Clean all surfaces of foreign material.
Oil Inlet Tube Removal
STEP 55 STEP 56
Remove the oil inlet tube bolts. Remove the oil inlet tube.

2445-15
STEP 57
Clean all surfaces of foreign material.
Oil Inlet Tube Installation

STEP 58 STEP 60
Install a new gasket. Install the oil inlet tube bolts and tighten to a tor-
que of 18 lb ft (24 Nm)(2.4 kgm).
STEP 59
Install the oil inlet tube.

2445-16
Oil Pan Installation

STEP 61
Install a new oil pan gasket. Tighten the bolts to a torque of 18 lb ft (24 Nm) (2.4
kgm).
STEP 62
STEP 65
Install the oil pan.

Install the oil pan drain plug and tighten.
Install the washers and bolts. The concave side of

the washer must be toward the oil pan.
NOTE: The reserves the right to make improvements in


Section
2455
COOLING SYSTEM
Thermostat, Water Pump, Fan Pulley

and Belt Tensioner
Written In Clear
And
Simg,le
English
CASE CoRPORATION Rae 8-26101 Printed in U.S.A.

2455-2
TABLE OF CONTENTS
SAFETY RULES ................................................................................... 3
SPECIAL TORQUES .............................................................................. 4
SPECIFICATIONS ................................................................................ 4
SPECIAL TOOLS ................................................................................. 4
SERVICING THE COOLING SYSTEM

Water Pump Removal .......................................................................... 5,6
Water Pump Installation ......................................................................... 6
THERMOSTAT REPLACEMENT
Thermostat Removal ........................................................................... 7,8
Thermostat Inspection ........................................................................... 9
Thermostat Installation ....................................................................... 9,10
COOLING INLET SERVICING

Coolant Inlet Removal .......................................................................... 11
Coolant Inlet Installation ..................................................................... 12,13
COOLING SYSTEM AIR REMOVAL ............................................................... 13
FAN PULLEY SERVICING

Fan Pulley Bracket Removal .................................................................... 14
Fan Pulley and Pulley Bracket Installation ....................................................... 15
BELT TENSIONER SERVICING

Belt Tensioner and Bracket Removal .......................................................... 16,17
Belt Tensioner and Bracket Installation ....................................................... 17,18

2455-3
SAFETY RULES
To remove the system pressure, slowly turn the
CAUTION Add coolant to the radia-
radiator cap counterclockwise to the FIRST stop.
tor only when the engine is stopped or
This will permit a gradual release of pressure with
slowly idling. To avoid being scalded
little coolant loss.
when the pressure-type filler cap is
being removed, turn the cap slowly to
Never put coolant in a hot engine. The engine
the first stop position to relieve pres-
block or cylinder head can get cracks because of
sure before removing the cap.
the difference in temperature between the metal
and coolant.
How to Clean the Cooling System
Clean the cooling system a minimum of one time 3. Remove the radiator cleaner solution. Flush the
each year. In areas where the water has minerals, system with clean water. Fill the system with
clean the system with more frequency. antifreeze and water for operation. Check the
hoses, radiator and water pump for leaks.
1. When the coolant is hot, open the radiator drain
valve and remove the engine block drain plug. NOTE: After the cooling system is completely
Close the valve and install the engine block filled, run the engine for approximately 20 minutes
drain plug after the system is empty. to remove all the air from the system. Check cool-
ant level and add coolant if needed.
2. Add a radiator cleaner and fill the system with
clean water. Use a good type of radiator
cleaner. Follow the instructions given with the
radiator cleaner.

2455-4
SPECIAL TORQUES
Water Pump Housing Bolts ...................................... 181b ft 24 Nm
(2.4 kgm)

(2.4 kgm)
Inlet Housing Bolts .............................................. 32 lb ft 43 Nm

(4.3 kgm)
Fan Pulley Bracket Bolts ......................................... 18 lb ft 24Nm

(2.4 kgm)
Fan Pulley Bolts (Grade 8.8) ..................................... 18 lb ft 24 nm

(2.4 kgm)

(3.4 kgm)
Tensioner Bracket Bolts ......................................... 18 lb ft 24 Nm

(2.4 kgm)
Tensioner Bolt .................................................. 32 lb ft 43 Nm

(4.3 kgm)
SPECIFICATIONS
Belt Tension:
Spring Tension at 35 degree angle (minimum) .................... 18 lb ft 24 Nm
(2.4 kgm)
SPECIAL TOOLS
TORQUE WRENCH LB FT

2455-5
SERVICING THE COOLING SYSTEM

Water Pump Removal
STEP 1
ilci.:
Lift the belt tensioner pulley and remove the fan

belt.
STEP4
Case 6-590 engine.

Remove the water pump.

2455-6
Remove the o-ring.
Water Pump Installation
Install the water pump bolts and tighten to a torque

of 18 lb ft (24 Nm)(2.4 kgm).
Install the water pump into the engine block.

Lift the belt tensioner pulley and install the fan belt.
IMPORTANT: See Step 41 through 43 to remove

the air from the cooling system.

2455-7
THERMOSTAT REPLACEMENT
Thermostat Removal
Lift the belt tensioner pulley and remove the fan Remove the alternator bracket bolts.
belt.
Remove the alternator bracket.

Remove the bolts that hold the alternator to the
brackets.
Remove the thermostat housing bolts.

'Ill'
Remove the alternator.

2455-8
Remove the thermostat housing assembly. Remove the seal from the thermostat housing.
Clean the thermostat housing mounting surface of Remove the thermostat from the thermostat hous-
all foreign material. ing.
Remove the engine lift bracket.

2455-9
Thermostat Inspection
STEP 21
THERMOSTAT OPEN
Check the thermostat for correct operation. Put

the thermostat in a container of hot water (approxi-
mately 175° F (79.4°C} water). The thermostat
should be completely open at 203°F (95°C). Re-
place the thermostat if it does not meet the above
specifications.
Thermostat Installation
~ LIFT BRACKET
SEAL ~ /
THERMOSTAT ~ ~~ ~
THERMOSTATHOUSING \ ~ •.
~
" ~
u.
~
~
!:)
Install the thermostat in the thermostat housing. Install the seal in the thermostat housing.
The thermostat must point out toward the radiator.
The tang on the thermostat must be in the slot of
the thermostat housing.

2455-10
Install the thermostat housing assembly. Tighten

••
Lift the belt tensioner pu ley and install the fan belt.
the bolts to a torque of 18 lb ft (24 Nm)(2.4 kgm).
IMPORTANT: See Step 41 through 43 to remove
the air from the cooling system.
Install the alternator bracket and tighten the bolts

to a torque of 18 lb ft (24 Nm)(2.4 kgm).

2455-11
COOLANT INLET SERVICING

Coolant Inlet Removal
a.
Lift the belt tensioner pulley and reniove the fan Remove the coolant inlet bolts.
belt.
Remove the coolant inlet.

Remove the bolts that hold the alternator.
Remove the o-ring. ·

Remove the alternator.

2455-12
Coolant Inlet Installation
0-RING
~
COOLANT INLET
$TEP 35
Install the coolant inlet bolts and tighten to a tor-

que of 32 lb ft (43 Nm)(4.3 kgm).
Install the coolant inlet. Install the alternator.

2455-13
STEP 40
Install the alternator bolts and tighten. Lift the belt tensioner pulley and install the fan
COOLING SYSTEM AIR REMOVAL

STEP 41. 6T-590 Engine
Loosen the plug on the

the air from the cooling system
NOTE: See the operators manual for the correct NOTE: See the operators manual for the correct
filling procedure. filling procedure.
Loosen the plug on the after cooler to remove the

air from the cooling system.
NOTE: See the operators manual for the correct

filling procedure.

2455-14
FAN PULLEY SERVICING

Fan Pulley Bracket Removal
Loosen the fan pulley bolts. Remove the bracket bolts.
Lift the belt tensioner pulley and remove the fan Remove the bracket.
belt.
Remove the fan pulley bolts and the fan pulley.

2455-15
Fan Pulley and Pulley Bracket Installation
STEP 49
-
Lift the belt tensioner pulley and install the fan belt.
'.
Install the pulley bracket bolts and tighten to a Torque the fan pulley bolts as follows:
torque of 18 lb ft (24 Nm)(2.4 kgm). Grade 8.8 ............ 18 lb ft (24 Nm)(2.4 kgm)
Grade 10.9 ........... 25 lb ft (34 Nm)(3.4 kgm)
Install the fan pulley and bolts.

2455-16
BELT TENSIONER SERVICING

Belt Tensioner and Bracket Removal
STEP
Lift the belt tensioner pulley and remove the fan Remove the bolts and the fan belt pulley.
belt.
STEP 55
Remove the belt tensioner bolt.
Use a precision typetorque wrench to lift the belt

tensioner to a 45 degree angle. Lower the belt Remove the belt tensioner.
tensioner to a 35 degree angle. The spring tension
must not be less than 18 lb ft (24 Nm)(2.4 kgm). If
the spring tension is less than 18 lb ft (24 Nm)(2.4
kgm) the belt tensioner must be replaced.
NOTE: Do not use a clik type torque wrench to

measure the spring tension. Revised 3-85 Printed in U.S.A.
Rae 8-26101
2455-17
Remove the Allen head bolts from the belt ten- Remove the belt tensioner bracket.
sioner bracket.
Belt Tensioner and Bracket Installation
~·
Install the belt tensioner bracket. Install the belt tensioner.
Install the Allen head bolts and tighten to a torque Install the belt tensioner bolt and tighten to a tor-
of 18 lb ft (24 Nm)(2.4 kgm). que of 32 lb ft (43 Nm)(4.3 kgm).

2455-18
STEP 67
Install the fan belt pulley and bolts. ·Torque the fan pul as follows:
Grade 8.8 ............ 18 Ib ft (24 Nm)(2.4 kgm)
Grade 10.9 ........... 25 lb ft (34 Nm)(3.4 kgm)
Lift the belt tensioner pulley and install the · n belt.

Section
2465
TURBOCHARGER
Written In Clear
And
Simple
English
IMPORTANT: This Turbocharger was made using the Metric Measurement

system. All measurements and checks must be made with metric tools to make
sure of an accurate reading when inspecting parts.

October, 1984
2465-2
TABLE OF CONTENTS
SPECIFICATIONS ................................................................................ 2
SPECIAL TORQUES .............................................................................. 3
SPECIAL TOOLS ......•.......................................................................... 3
SERVICING THE TURBOCHARGER

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4,5
Inspection ...................................................................................... 6
Disassembly .........•.........................•............................................. 7-13
Inspection After Disassembly ................................................................ 13-14
Assembly ........................................•..••...................................... 15-22
Installation ...............................................................•.................. 23,24
SPECIFICATIONS
Metric Value
Turbine Wheel Horizontal Movement ............................................•..... 0.10 to 0.16 mm

2465-3
SPECIAL TORQUES
Turbine Housing Bolts ........................................ 96 lb inch 11 Nm
(1.1kgm)
Center Housing to Back Plate Bolts ............................ 48 lb inch 6 Nm

(0.6 kgm)
Compressor Housing Bolts .................................... 48 lb inch 6 Nm

(0.6 kgm)
Compressor Lock Nut ....................................... 120 lb inch 14 Nm

(1.4 kgm)
Thrust Bearing Screws (Torx Head) ........................... 36 lb inch 5 Nm

(0.5 kgm)
Turbocharger Mounting Nuts .................................... 24 lb ft 32 Nm

(3.2 kgm)
Drain Tube Bolts ................................................ 18 lb ft 24 Nm

(2.4 kgm)
SPECIAL TOOLS
CAS-10032 LB INCH TORQUE WRENCH

CAS-10033 LB FT TORQUE WRENCH
CAS-10066-1A DIAL INDICATOR

2465-4
SERVICING THE TURBOCHARGER

Removal
STEP 1 STEP 4
Turbocharger with the air cleaner and the exhaust Disconnect the oil supply tube.
pipe removed.
STEP 5
STEP 2
Disconnect the oil supply tube clamp from the

Loosen the air intake hose clamps. turbocharger.
STEP 3 STEP 6
Remove the air intake hose. Disconnect the oil drain tube.

2465-5
STEP7
Remove the nuts that hold the turbocharger to the the mounting surface on the
exhaust manifold. and the exhaust manifold.
STEP 8 STEP 11
Remove the turbocharger from the exhaust mani- Clean the mounting surface on the turbocharger
fold. and the oil drain tube.
STEP 9
Remove the gasket.

2465-6
Inspection
STEP12 STEP13
Put the turbocharger on a clean work surface. Use a dial indicator to check the horizontal move-
ment of the turbine wheel assembly. The horizon-
tal movement must not be more than 0.10 to 0.16
mm. The turbocharger must be rebuilt if the move-
ment is more than 0.16 mm or less than 0.10 mm.
Rae 8-26110 ~ssued 10-84 Printed in U.S.A.

2465-7
Disassembly
STEP 17
Put a identification mark on the compressor hous- Remove the compressor housing clamp plates.
ing and back plate. This identification is to make
sure the parts are in the correct position at assem-
bly. STEP18
STEP 15
Lift the assembly off the compressor housing.
Put a identification mark on the turbine housing STEP19

and the back plate. This identification is to make
sure the parts are in the correct position at assem-
bly.
STEP 16
Make the tabs straight on the lock plate.
Remove the retaining bolts from the compressor

housing.
2465-8
STEP 20
Put the turbine end ofthe center housing assembly

into the holding fixture.
STEP 21
STEP 24
Remove the lock plates and

turbine housing. Use a doub universal joint to remove the com-
pressor wheel lock nut. This procedure will pre-
vent the turbine shaft from bending.
STEP 22
STEP 25
Lift the center housing assembly from the turbine

housing.
Remove the compressor wheel lock nut.
NOTE: The compressor whee/lock nut is left hand

thread.

2465-9
STEP 26
Remove the com pressor wheel.
STEP 27
Lift the center housing from the turbine shaft. STEP 30
STEP 28
Remove the heat shield.

2465-10
STEP 31 STEP 34
Make the tabs straight on the lock plate. Remove the center housing from the back plate.
STEP 32 STEP 35
Remove the retaining bolts from the center hous- Remove the oil baffle from the back plate.
ing.
STEP 36
STEP 33
Remove the seal from the back plate.

Remove the lock plates from the center housing.

2465-11
STEP 37 STEP 40
Remove the oil slinger from the back plate. Remove the torx head screws from the center
housing.
STEP 38
STEP 41
Remove the seal ring from the oil slinger.

Remove the thrust bearing.
STEP 39
STEP 42
Turbocharger center housing.

Remove the thrust collar.

2465-12
STEP 43 STEP 46
Remove the outer bearing retaining ring. Turn the center housing over and remove the outer
bearing retaining ring.
STEP 44
STEP 47
Use a wire hook and pull the bearing from the

center housing. Use a wire hook and pull the bearing from the
center housing.
STEP 45
STEP 48
Remove inner bearing retaining ring.

Remove the inner bearing retaining ring.

2465-13
STEP 49
Center housing disassembled.
Inspection After Disassembly

STEP 50 STEP 52
Replace the turbocharger if the outlet openings Replace the turbocharger if the turbine wheel is
show warpage or cracks. damaged or if the turbine shaft has grooves or
scratches.
STEP 51
STEP 53
Replace the turbocharger if the compressor hous-

ing shows damage caused by wheel friction. Replace the turbocharger if the back plate has
wheel friction wear.

2465-14
STEP 54 STEP 56
Inspect the compressor wheel for bent blades and Replace the turbocharger if the oil slinger shows
scratches. Replace the turbocharger if the wheel damage.
shows damage.
STEP 57
STEP 55
Inspect the center housing bearing surfaces for

Replace the turbocharger if the heat shield shows scoring or scratches. Replace the turbocharger if
damage. there is damage.

2465-15
Assembly
COMPRESSOR HOUSING
SEAL
r........
I
I
I
I
l RETAINING RING
\,o(/
/(fbf) 0
BEARING
CENTER HOUSING
CLAMP PLATE
LOCK PLATE CLAMP PLATE
TURBINE HOUSING
NOTE: Lubricate all bearings, seals and the tur-

bine shaft with clean engine oil before assembly.

2465-16
STEP 58 STEP 61
Install a new inner bearing retaining ring. The Turn the center housing over and install a new
round edge of the retaining ring must be toward inner bearing retaining ring. The round edge ofthe
the top. retaining ring must be toward the top.
STEP 59 STEP 62
Install a new center housing bearing. Install a new bearing in the center housing.
STEP 60 STEP 63
Install a new outer bearing retaining ring with the Install a new outer bearing retaining ring with the
round edge down. round edge down.

2465-17
STEP 64 STEP 67
Install the thrust collar with the large OD down. Tighten the thrust bearing screws to a torque of 36
lb inch (5 Nm)(0.5 kgm).
STEP 65
STEP 68
Install a new thrust bearing on the center housing.

Install the oil baffle on the center housing with the
cup side down.
STEP 66
STEP 69
Install new torx head screws in the center housing.
Install a new seal ring on the oil slinger.

2465-18
STEP 70 STEP 73
Carefully install the oil slinger in the back plate. Install new lock plates and new mounting bolts.
STEP 71 STEP 74
Install a new seal in the back plate. Tighten the back plate mounting bolts to a torque
of 48 lb inch (6 Nm)(0.6 kgm).
STEP 72
STEP 75
Install the center housing on the back plate. Make

sure the mark on the back plate and the center Bend the tabs on the lock plate.
housing are aligned.

2465-19
STEP 76
Install a new seal ring in the groove of the turbine Install the compressor wheel on the turbine shaft.
wheel.
STEP 80
STEP 77
Install a new compressor wheel lock nut.

Install the turbine wheel in the fixture and install
the heat shield on the turbine wheel. NOTE: The compressor whee/lock nut is left hand
thread.
STEP 78
STEP 81
Install the center housing on the turbine shaft. Be

careful not to damage the seal ring. Use a double universal joint socket to tighten the
lock nut on the compressor wheel. This procedure
will stop the turbine shaft from bending.

2465-20
STEP 82 STEP 84
Tighten the lock nut to a torque of 120 lb inch (14

Nm)(1.4 kgm).
STEP 83
Carefully install the center housing on the turbine

housing. Make sure the mark on the turbine hous-
ing is in align with the.mark on the center housing.
Remove the center housing assembly from the fix-

ture. STEP 85
Install the clamp plates and the new lock plates.

2465-21
STEP 86 STEP 89
Install the new turbine housing bolts and tighten to Install the compressor housing mounting plates.
a torque of 96 lb inch (11 Nm}(1.1 kgm).
STEP 90
STEP 87
Install new lock washers and bolts in the compres-

Bend the tabs on the lock plates. sor housing. Tighten the bolts to a torque of 48 lb
inch (6 Nm}(0.6 kgm).
STEP 88
STEP 91
Install the turbine h assembly on the com-'

pressor housing. Make sure the mark on the center Turbocharger completely assembled.
housing is in align with the mark on the compres-
sor housing.
Issued 10-84 Printed in U.S.A.

Rae 8-26110
2465-22
COMPRESSOR HOUSING TUBINE HOUSING

2465-23
Installation
STEP 92 STEP 95
Install a new gasket on the exhaust manifold. Install a new gasket on the oil drain tube.
STEP 93 STEP 96
Install the turbocharger on the exhaust manifold. Install the oil drain tube bolts and tighten the bolts
to a torque of 18 lb ft (24 Nm)(2.4 kgm).
STEP 94
STEP 97
Install the turbocharger mounting nuts and tighten

to a torque of 24 lb ft (32 Nm)(3.2 kgm). Install and tighten the bolt for the oil supply tube
clamp.

2465-24
STEP 98 STEP 100
Connect and tighten the oil supply tube to the Install and tighten the air intake hose clamps.
turbocharger.
STEP 101
STEP 99
Turbocharger installed on engine.

Install the air intake hose.
NOTE: The cAsE coRPORATION reserves the right to make improvements in


Section
2565
TURBOCHARGER FAILURE ANALYSIS
CASE CORPORATION
700 State Street
Racine, WI 53404 U.S.A.
CASE CANADA CORPORATION
© 1996 Case Corporation
3350 South Service Road Printed in U.S.A.
Burlington, ON L7N 3M6 CANADA Rae 9-78235 February, 1996
2565-2
CAUSES OF PREMATURE TURBOCHARGER FAILURE
Certain operating and maintenance conditions Push in the fuel shutoff control and press
can arise which could cause premature turbo- the start button. Run the engine (about 2 min.
charger failure. NOTE: The total solution to max.) at 1000 RPM until normal engine oil
the problem is not in repairing the failure, but pressure shows on the engine oil pressure
in determining the cause. Replacing a damaged gauge assuring proper lubrication to the tur-
turbocharger without determining the cause will bocharger.
frequently result in a repeat failure. 4. If the engine fires and stops, wait for the star-
ting motor to stop spinning before attempting
Lack of Lubricating Oil another start.
5. Do not use the starting motor longer than 30
This type of failure can occur when the a- seconds without interruption. Wait at least
mount of oil being supplied to the turbocharger 3 minutes between crankings so batteries
is insufficient to lubricate or cool bearing can recuperate and the starting motor can
and journal surfaces. cool.
6. Should the engine kill when operating under
Operating temperatures affect the volume load, immediately restart the engine to
of oil required by the turbocharger. As turbo- prevent over-heating caused by stopping the
charger speed or engine load increases, the flow of oil for turbocharger, cooling and
need for lubricating oil increases. NOTE: In- lubrication.
sufficient oil for periods as short as five sec-
onds can cause failure. This is why it is nec- Foreign Material or Dirt in the
essary to prime the turbocharger as part of
the everyday operating procedure. IMPOR- Lubricating System.
TANT: It is very important that adequate Operating the engine with contaminated oil
lubrication reaches the turbocharger bear- will cause damage to the turbocharger bear-
ings and throughout the engine before opera- ings if the particles are of sufficient quantity.
ting the engine at rated speed. If the particles are large enough, they can
clog the internal oil passages and starve the
Priming .The Turbocharger bearings. This is another reason why it is im-
portant to change the engine crankcase oil and
1. Place the transmission range shift lever in oil filters at regular specified intervals.
"N" Neutral position.
Foreign Material in Exhaust or
2. Set the throttle lever not more than 1/3 open Air Intake Systems.
position (1000 RPM).
The rotating parts of the turbocharger can be
3. Push in the fuel shutoff control. Press starter damaged by particles introduced through the air
button until engine starts. IMPORTANT: Do intake, which makes proper maintenance of the
not increase throttle or apply load until nor- air cleaner system very important.
mal oil pressure shows on the engine oil
pressure gauge, assuring proper lubrication High Exhaust Temperature
to the turbocharger.
Excessive temperature in the exhaust system
IMPORTANT: In very cold weather, at oil will cause lubricating oil to coke in the center
filter change or when the tractor has been housing drain annulus at the turbine end. Oil
idle for several weeks or more, proceed as leakage, carbon deposits and eventual damage
follows to prime the turbocharger. to the back of the turbine wheel will result.
High exhaust temperature can also erode the
Pull out the fuel shutoff control, press the turbine housing creating pitting and deposits
start button and hold. Allow the engine to on the turbine wheel.
crank until the engine oil pressure gauge High exhaust temperature can be caused by
pointer reaches the green zone. Do not the turbocharger itself. Carbon build up on the
exceed 30 seconds cranking time. turbine wheel, if severe, will slow the rotating
assembly, reducing the amount of inlet air.
2565-3
TURBOCHARGER FAILURE ANALYSIS
NOTE: Following are discussion and examples

of damaged parts which are typical turbocharger
failures. In analyzing turbocharger failure it is
important to recognize what caused the failure.
Replacing of the, parts will, of course, repair
the damage but, unless you can correct the
causes, a reoccurance of these problems can be
expected.
Turbine Contact Damage Compressor Contact Damage
Contact damage to the turbine usually means

there was bearing damage and/ or shaft motion
caused by lack of lubricant or contaminated
oil. In this picture we see the turbine end
showing wheel rub from bearing failure as a
result of oil starvation.
Damage to bearings from contaminated lub-

ricant or from lack of lubricant will allow
motion of the shaft, permitting the compressor
wheel to contact the housing. Marking will be
visible on both the housing and the compres-
sor wheel. In these pictures we see the com-
pressor end showing wheel rub from bearing
failure as a result of oil starvation.
2565-4
Coked Center Housing Scored Bearing Surface
Coked (sludged) center housing failures are The bearing surfaces of this shaft were scored
generally caused by high exhaust temperatures due to dirty engine oil. Evidence, of a contamina-
due to over-fueling, over-loading the engine, ted oil failure calls for careful, thorough exa-
dirty engine oil, or plugged oil return. Also mination of engine lube system.
examine bearings for sludge.
Scored Bearings
Scored Turbine Shaft
Scoring on the inside and outside surfaces

The scoring of this shaft was caused by a of the bearings is definitely attributed to
loose compressor wheel lock nut. dirty engine oil.
2565-5
Scored Thrust Collar ~Compressor Damage - Hard
Scoring on the thrust collar caused by dirty

oil usually because engine oil and/ or oil filters
were not changed at the recommended intervals.
Compressor Damage - Soft
Hard material such as a nut, wire, wrench

or bolt getting into the inlet will damage the
compressor blades as shown. The compressor
housing will be marked by the bits of foreign
material. If damage to blades is so extensive
that wheel balance is destroyed, some wheel-
to-housing contact damage may also be pre-
Soft material getting into the inlet will dam- sent.
age the compressor blades as shown. The
damage to this blade was caused by a shop
towel being left in the intake system.
2565-6
Compressor Blade Erosion Turbine Shaft Discoloration
Erosion of compressor blades from ingestion Discoloration of the turbine shaft is due to
of dust. Blades on one wheel are thinned while overheating caused by oil starvation. Lack of
the other wheel is almost completely worn lubrication generally is a matter of improper
away. Fine erosion of the inlet edges of the start-up or shut-down practices.
compressor wheel suggests sand or other fine
abrasive in the inlet system, entering through
a damaged air cleaner element or a leak in
inlet piping. There will generally be no dam- Backing Plate Wheel Rub
age to the turbine wheel or bearings unless the
problem was so severe that the rotating unit
became unbalanced.
Turbine Wheel Damage
Wheel rub against the backing plate can be

caused by a bent shaft or improper assembly.
Foreign material in the exhaust system will

cause chipped or broken turbine wheel blades.
Foreign material is usually something left by
accident in the exhaust manifold, or debris from
an engine component such as a valve which failed.
If damage is extreme, the turbine wheel balance
will be destroyed and further damage will occur.
If you find this problem checkout the engine.
2565-7
Blade Edges Lifted Bearing Damage
Blade edges of the compressor wheel lifted Engine bearing material imbedded in the
by improper removal of the compressor hous- bearing surfaces. Checkout the engine for
. ing. Housing should not be pried off but lifted possible bearing failure.
straight off.
Bearing Failure
Turbine Shaft & Bearings
Bearing failures occur in two separate

Turbine shaft and bearings showing effect of areas. Scoring on the inside as well as the
oil starvation. outside is attributed to dirty oil. Abrasive
wear can also cause erosion around the oil
holes in the bearings. A good bearing is shown
in the lower right for comparison.
2565-8
Fine Scratches on Shaft Bent or Broken Shaft
Fine scratches on both bearing journals are Bearing damage and extreme shaft motion
evidence ·that abrasive material has contamina- caused by lack of lubrication or abrasives in
ted the lubricating oil. the oil may eventually cause the shaft to bend
or even break. When this type of damage is
evident, check the bearings.
NOTE: The Case "Company reserves the right to make improvements

in design or changes in specifications at any lime without incurring any
obligation to install them on units previously sold.
3001
FUEL LINES, FUEL TANKS, AND ENGINE CONTROLS
TABLE OF CONTENTS
Specifications .......................... 3001-2 Replacement of the Fuel Filtees . . . . . . . . . . 3001-5
Throttle Linkage Adjustment ............ 3001-2 Removing Water From the Fuel System .. 3001-6
Illustration - Throttle Linkage ........... 3001-3' Illustration - Fuel Lines ................. 3001-7
Removing Air From the Fuel System ..... 3001-4 ' Illustration - Fuel Tank .................. 3001-8
Written In Clear
And
Simple
English

3001-2
SPECIFICATIONS
Engine Speeds
Low idle .................................................................... 750 to 800 rpm (r/min)
Maximum no load speed ................................................... 2095 to 2175 rpm (r/min)
THROTTLE LINKAGE ADJUSTMENT

1. Disconnect the throttle rod at the fuel injection b. On engines with a turbocharger the arm is
pump. moved forward from the stop at least 1/16 inch
(1.5 mm).
2. Use a photo tachometer or other tachometer of
equal accuracy and check the engine speeds. If the
engine speeds are not equal to the specifications
on this page, adjust the stop bolts or the fuel injec-
tion pump.
3. Move the hand throttle to the bottom of the slot

in the instrument panel.
4. Check to see that the top of the stop bolt for the
accelerator pedal is 3-1/4 inches (83 mm) from the
floor plate. Adjust as required.
5. Adjust the length of the throttle rod at the fuel

injection pump so that:
a. On engines without a turbocharger there is

6. Pull the hand throttle up until the accelerator
at least a 1/16 inch (1.5 mm) space as shown
pedal touches the stop bolt. If the accelerator ped-
below.
al does not touch the stop bolt, adjust the length of
the hand throttle rod.
7. Adjust the length of the accelerator rod at the

fuel injection pump so that:
a. On engines without a turbocharger there is

at least a 1/16 inch (1.5 mm) space as shown
below.
3001-3
1. Hand Throttle 4. Cross Shaft 6. Hand Throttle Rod

2. Stop Bolt 5. Connects To Arm 7. Accelerator Pedal Rod
3. Accelerator Pedal On Fuel Injection Pump 8. Throttle Rod
Throttle Linkage
3001-4
REMOVING THE AIR FROM THE FUEL SYSTEM

1. If necessary, fill the fuel tank.
2. Make sure that the fuel tank shutoff valves are

in the ON position.
1. Fuel Tank Shutoff Valves (Also As4s743
See Page 3001-8)

8. Operate the hand primer until fuel with no air
flows from around the vent screw.
3. Loosen the vent screw on the filter head 1 to 2
turns.
9. Tighten the vent screw.
4. Operate the hand primer until fuel with no air
10. Push the hand primer lever up into the STOR-
flows from around the vent sc
AGE position.
11. Start the engine and check for fuel leaks at the
filters.
12. If the engine starts but does not run correctly:
a. Run the engine at 1000 rpm (r/min).
b. Loosen each fuel line at the fuel injector

until fuel with no air flows from around the
fitting. Tighten the fuel lines.
1. Vent Screw on Filter Head All46415
2. Hand Primer c. Continue this procedure until there is no

air in the fuel lines.
5. Tighten the vent screw. 13. If the engine does not start
6. Put the fuel shutoff switch in the ON position. a. Run the engine with the starter.
b. Have another person loosen each fuel line

at the fuel injectors until fuel with no air flows
from around the fitting. Tighten the fuel line.
c. Continue this procedure until there is no

air in the fuel lines.
on njection Pump
(Turbocharged Engines)
3001-5
REPLACEMENT OF THE FUEL FILTERS

1. Park the machine on a level surface. 6. Loosen the drain valve in the primary fuel filter
and drain the primary fuel filter.
2. Lower the attachments to the floor. If the ma-
chine has a loader, raise the loader frame and lower 7. Turn the filters counterclockwise and remove
the support strut onto the piston rod. Then lower the filters from the filter head.
the loader frame until the support strut touches the
lift cylinder. 8. Apply a thin layer of clean oil to the gasket of
each new filter.
3. Stop the engine and apply the parking brake.
9. Install the filters. Use your hands to tighten the
4. Close the fuel shutoff valves at the fuel tank. filters 1/2 turn after the filters make contact with the
filter head.
5. Clean the filter head and the outside of the fuel
filters. 10. Loosen each filter approximately one turn.
11. Tighten the filters until the filters are touching

the filter head and then tighten 1/2 to 3/4 turn. Do
not use a strap wrench.
12. See Removing Air From the Fuel System on

page 3001-5 and remove the air from the fuel sys-
tem.
Primary
Secondary Fuel Filter
Filter Head
3001-6
REMOVING WATER FROM THE FUEL SYSTEM

Check the primary filter for water and sedi- 6. Drain the primary filter until all water and sedi-
ment after every 50 hours of operation. ment has been removed.
1. Park the machine on a level surface. 7. Tighten the drain valve.
2. Lower the attachments to the floor. If the ma- 8. Install the side panel.
chine has a loader, raise the loader and lower the
support strut onto the piston rod. Then lower the 9. If there was any water or sediment in the pri-
loader frame until the support strut touches the lift mary filter, do step 10.
cylinder.
10. The drain valve for the fuel tank is in the left
3. Stop the engine and apply the parking brake. rear corner of the bottom of the fuel tank. Loosen
the valve until the fuel starts to flow.
4. Remove the side panel from the left side of the
engine compartment. 11. Continue to drain the fuel tank until all water
and sediment has been removed.
12. Tighten the drain valve.

3001-7
850711
1. Fuel Return Line At Tank 3. To Fuel Pump

2. Fuel Supply Line At Tank 4. From Fuel Injectors
Fuel Lines
3001-8
1. Fuel Gauge 2. Cap 3. Tank
Fuel Tank
Section
3410
FUEL SYSTEMS AND FILTERS
Written In Clear
And
Simple
English

3410-2
SPECIFICATIONS
Filter Replacement (First and Second Stage) ........................... Every 500 hours or when loss of
engine power occurs
First Stage Filter .............................................................. Full Flow, turn on type
Second Stage Filter ........................................................... Full Flow, turn on type
Fuel System Operating Pressure ........................................................... 5 to 7 PSI
(34.475 to 48.265 kPa)
(3.448 to 4.827 Bar)
For Acceptable Number Two Diesel Fuel
A.P.I. Gravity (Min) ............................................................................... 30

OPour Point (Max) .................................. 10° F (5° C) below ambient operating temperature.
Distillation (90% Point) ................................................... 540 to 625° F (282 to 329° C)
Flash Point (Min) ................................................................ 125° (52°C) or legal
Kinematic Viscosity Centistokes
At 100° F (38° C) ................................................................ 2.0 to 4.3 Seconds*
Cetane Number (Min) .............................................. 40 (45 to 55 For Cold Temperature
or High Altitude Use).
Water and Sediment Volume (Max) ............................................................. 0.05%
Ash Weight (Max) ............................................................................. 0.01 o
Sulphur Weight (Max) .......................................................................... 0.5°
Carbon Residue or 10° Residuum (Max) ......................................................... 0.2°
Corrosion, Copper Strip, 3 hours at 212°F (100°C) .......................................... Number 3
(* 32 to 40 Saybolt Universal Seconds)
FUEL SYSTEM
Filter Removal and Installation
NOTE: At the first filter change and each filter NOTE: When the filters are too tight, you can
change after that, always install filter kit, Case Part cause damage to the gaskets and filters.
Number A77470.
5. Make sure there is fuel in the fuel tank.
1. Clean the filter head, elements and the engine
area next to the filters. 6. Loose the air removal screw above the filter
head. Actuate the hand primer pump. Close the
2. Remove the drain plug from the first stage filter. air removal screw when clear fuel with no air
bubbles flows from the screw.
3. To remove the filters, use a clamp type filter
wrench. 7. The ignition switch must be turned to the ON
position to energize the fuel shutoff solenoid.
4. Put a small amount of clean oil or grease on the Do not turn the engine over until Step 8 is com-
seals of the new filters. Install the filters. Turn pleted.
the filters clockwise until the seal comes in con-
tact with the filter head. Use your hand to 8. Loosen the air removal screw on the fuel injec-
tighten the filter one half of a turn. To get the tion pump. Actuate the hand primer pump, close
correct seal, loosen the filters and again tighten the air removal screw when clear fuel with no air
one half to three fourths of a turn after the seal bubbles flows from the screw. Actuate the hand
comes in contact with the filter head. primer pump five more times to finish the air
removal.

3410-3
Filter Replacement and Air Removal

STEP 1
Case 6T-590 engine. Use a clamp wrench to remove the fuel filters.
STEP 3
Lubricate the filter seal a small amount before in-

stallation.
Case 6-590 engine.

3410-4
STEP 4 STEP 6
Turn the filters clockwise until the Iter seal makes Turn the ignition switch to the ON position to ener-
contact with the filter head. Use your hand to gize the shutoff solenoid. Loosen the air removal
tighten the filter one half of a turn. To get the screw on the fuel inlet line. Actuate the hand
correct seal, loosen the filters and again tighten primer pump. Close the air removal screw when
the filters one half to three fourths of a turn after clear fuel with no air bubbles, flows from the screw.
the seal makes contact with the filter head When
the filters are too tight, you can cause damage to NOTE: If the hand lever on the primer pump can
the seals and filters. not be actuated, turn the engine until the pump can
be actuated.
STEP 5
Make sure there is fuel in the fuel tank. Loosen the

air removal screw and actuate the hand primer Turn the ignition switch to the ON position to ener-
pump. Close the air removal screw when clear fuel gize the shutoff solenoid. Loosen the air removal
with no bubbles flows from the screw. screw on the injection pump. Actuate the hand
primer pump. Close the air removal screw when
NOTE: If the hand lever on the primer pump can clear fuel with no air bubbles, flows from the screw.
not be actuated, turn the engine over until the
pump can be actuated. NOTE: If the hand lever on the primer pump can
not be actuated, turn the engine until the pump can
be actuated.
NOTE: The CASE coRPORATION reserves the right to make improvements in


Section
41
INJECTION PUMP
Pump Drive Gear, Timing Pin, Fuel

Shutoff Solenoid, Primer Pump, and Pump Timing
Written In Clear
And
Simp.fe
English

October, 1984 (Revised March. 1985)
3412-2
TABLE OF CONTENTS
SPECIAL TOOLS · ..•........•...............•...................................•................. 2
SPECIAL TORQUES ........•.•••..•.....•.........•. ; ••...•..............•........•............... 3
GENERAL INFORMATION .......•.•. ; ..............•.............................................. 3
TROUBLESHOOTING GUIDE ..•..•.•....•..........•.•..••.............•....•.................... 4
SERVICING THE FUEL SYSTEM

Injection Pump Removal .....•.....................•.......................................... 5-10
Injection Pump Installation .................................................................. 11-15
Injection Pump Gear Removal ..•.•.....•...•..•..•.......••...............•.................. 16-18
Injection Pump Gear Installation ........•......•.........••........................•......... 19-21
TIMING LOCK PIN

Removal • • . . • . • . . • . • . . . . . . . . . . . . • • . . . . • • . . • . . . . • • • . . • . • . . . . . . . . . . . . . . • . . • . . . . • . . . . . . . . . . . . . . 21 ,22
Installation • • • . • . . . . • . . • . . . . . • . • . . . . . . • • • . . . . . . . . . • • . . . . . . . . • . . . . • . . . • . . . . . . . . . . . . . . . • . . . . . . . . . 22
FUEL SHUTOFF SOLENOID

6T-590 and 6TA-590 Engine ..•.........•.•....•...•.•...•....................•............•..... 23
6-590 Engine .............•.....•.....•.........•.•••..•........•.....•..•...........••......... 24
PRIMER PUMP
Removal ...••....••...........•••............••.•.•.....•..................•..........•.•...... 25
Installation . . • . . . . . . . • • . . . . • . . . . • . • . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,27
INJECTION PUMP TIMING

6-590 Engine ..•.•••....•••..•...•....••.•...••••.•.........•.....•.•.•.•...•................ 28-31
6T-590 and 6T A-590 Engine • . . • . • . . . • • • • . • • • . • • . . • . • . . . . . . • . • . . . . . . . . . . . . . • . . . . . . . . . . . . • . . . . . 32-37
SPECIAL TOOLS
CAI-1891 GEAR PULLER
CAI-1690 ENGINE TORQUE WRENCH LB FT

TURN OVER TOOL
CAI-1745
DIAL INDICATOR
Rae 8·26141 Revised 3-85 Printed in U.S.A.

3412-3.
SPECIAL TORQUES
Injection Pump Mounting Bolts .................................. 181b ft 24Nm
(2.4 kgm)
Injection Pump Nut .......•................•..•................•. 48 lb ft 65 Nm

(6.5 kgm}
Fuel Line Inlet Bolt .............................................. 181b ft 24Nm

(2.4 kgm)
Fuel Shutoff Solenoid, 6T-590 and 6TA-590 Engine •••............. 321b ft 43Nm
(4.3 kgm)
Fuel Shutoff Solenoid, 6-590 Engine ...••...•..................... 10 lb ft 15 Nm

(1.5 kgm)
Leak Off Fitting . . • . . . • . . . . . . • . . . • • . . . • • . . . . . . • . . . . . . • . . . • . . . . . • . 18 lb ft 24Nm

(2.4 kgm)
Crankshaft Pulley Bolts ........ , ................................ 101 lb ft 137 Nm

13.7 kgm)
Injection Pump Lock Bolt ......•..............•..•..•....••..•... 22 lb ft 30Nm

(3.0 kgm)
Fan Pulley Bolts (Grade 8.8) ...................................... 18 lb ft 24Nm

(2.4 kgm)
Fan Pulley Bolts (Grade 10.9) · .••.•..•••..•....••..•• , ..•..•••.••. 25 lb ft 34Nm

(3.4 kgm)
Injection Pump Plug •..••...•....••...•..•.•..•.•.•..•....•.•••.. 17 lb ft 23Nm

(2.3 kgm)
GENERAL INFORMATION
The function of the Injection pump is to supply the It is very important that you take extra care to
correct amount of fuel under pressure to the fuel prevent any dust or foreign material from entering
injectors. The fuel must be pressurized with accu- the fuel system when service is done on the fuel
rate 'timing to the engme firing order. system.

Troubleshooting guide
for the diesel fuel injection system.
NOTE: It is assumed that the engine is In good

working order and properly tuned, and that the
electrical system has been checked and repaired
as necessary.
CAUSE t RE~EDY
Improper fuel in the tank t Drain tank, flush system, fill with
n~nru•u fuel
Tank empty or tank vent blocked t Fill tank/bleed system, check

tank vent (See Section 341
Air in the fuel system t Bleed fuel system, eliminate air leaks (See
Sect 341
Pump rear support bracket loose t Replace as necessary (See
Section 341
Voltage
Injection nozzle defective t Repair or replace (See Section 3413)
Engine air filter blocked t Replace air fitter element
Fuel injection pump defective or cannot be adjusted t Replace

Sect1on 341
Rae S..26141 Revised 3-85 Printed In u.s.A.

3412-5
SERVICING THE FUEL SYSTEM

Injection Pump Removal
STEP 1 STEP2
STEP3

3412-6
STEP&
Remove the fuel inlet Jine . covers In

the fuel inlet holes and on the fuel intet line con-
nection.

3412-7
Remove the . . and gaskets. Install a Disconnect the leak off fine. tnstall a dust
dust cover in the teak off hole in the injection the injection pump and on the leak off line.
pump.
pump.
covers in
the fuel inlet holes and on the fuel Inlet line con-
nections.

3412-8
STEP 18
Install the engine turn over tool, push in on the lock

pin and turn the engine over until the lock pin
engages into the camshaft gear.
IMPORTANT: Make sure there is a precision mark

on the injection pump and front cover.

3412-9
Loosen the nuts and the bracket bolt

injection pump to the front housing.
NOTE: The slot washer will be loose after the lock

IMPORTANT: If the key for the injection pump

shaft is not on the pump shaft when the pump is
removed, the front cover must be removed to re-
move the pump shaft key.
Loosen the· bracket and the· nuts that hold the In-
jection pump to the front housing.
Rae 8--26141 Revised 3-85 Printed in U.S.A.

3412-10
Remove the gear puller from the injection· pump Clean the injection pump mounting surfaces of all
drive gear. foreign material.

3412-11
Injection Pump Installation
Install a new gasJ<et. Align the · on the Injection pump and the front
housing. Install the nuts that . t)old the injection
pump to front housing and the bracket bolt.
NOTE: A new or rebuilt injection pump will have a

mark on the pump flange.
Install the injection pump. Make sure the slot In the

drive gear and the key in the injection pump shaft
are aligned.
NOTE: If the front cover was removed see Section

2425 for installation.
Install the washer and nut on the Injection pump

shaft and tighten a small amount. Loosen' the pump shaft tock bolt.
RaeB-26141 Revised 3-85 Printed in U.S.A.

3412-12
STEP 36
Install the slotted tab andtighten the Jock bolt to a

Tighten the nut to a torqUe of

kght);
,LOCK
......
;~; ..
·--"'·····~··,..
Loosen the lock bolt on . pump. move

the slot washer on the lock bolt. ilght~ the lock
NOTE: The slot washer will not move after the lock
Rae 8-26141 Revised 3-86 Printed in U.$)S;,

3412-13
Nm)(2.4 kgm).
Rae &-26141 Revised 3-85 Printed.in U.S.A.

3412-14
new gaskets.
must be a gasket on each side of the fuet intet line.
Connect
tion pump.
(24 Nm)(2.4 kgm).
Rae ~26141 Revised 3-85 Printed in U.S.,A.

3412-15
To rtmctve the -'r · fuel system see Section

Connect the to the fuel Injectors and 3410 in. the service manual.
the injection pump. tighten the Injector lines a
small amount.

3412-16
Injection Pump Gear Removal
Loosen the fan pulley bolts. Remove -the crankshaft puttey belts.
Lift the belt tensioner and remove the fan.
Remove the puiJey bolts arid the f~n pulley. Rernove'the front cbver botts~
Rae 8-26141 Revised 3--85 Printed in U.S.A.

3412.:.17
Remove the front 'CoYer. Remove the plug from the flywheel housing.
lnel4ll the engine turn over tool. Turn the engine

eign .materi't over and push the lock Jin into the camshaft gear.
NOTE: Make s(Jre there Is a mark on the injection

pump and front cover. .
STEP~
Looser{ the nl.rt on the lnje'Ction pump shaft.
·Loosen the pump lock arid slot

washer off the lock bolt shoulder. Tighten the lock
NOTE: The slot washer will be loose after the lock

Rae 8-26141 Revised 3-:85 Printed in U.SA

3412-18
Remove the nut and washer from the injection

pump shaft.
tnstaU the ges~ putter and push the d"*vegear off

the injection pUmp shaft, until the gear is loose.
Tighten,the toc;k bolt ~to a torque of 22 lbft (30

Nm)(3.0 kgm). ~ ··
Remove the drive gear from the injection pump

shaft.
Rae &-26141 Revised 3-85 Printed in U.S.A.

3412-19
Injection Pump Drive Gear Installation·

STEP70
Loosen the lock bolt.
LETTER A = 4-390
Install the'dtive gear on the injection pump shaft.

Make sure the cc)rrecftetter on drive gear and the
timing mark on the camshaft gear are in align.
NOTE: The slot In the drive gear and the key In the
lnjecflon pump shaft must be in align.
Install the slotted tab .ttgtlten the lock bolt to a

Install the washer and nut on the Injection pump

shaft and tighten a smelt amount.
Rae 8-26141 Revt8ed 3-85 Printed in U.S.A.

3412-20
STEP 74
Loosen pump · move the slot

washer on the lock' bolt. Tighten the lock bOlt to a
torque of 22 lb ft (30 Nm)(3:o kgm).
Clean the with loctite safe-

ty solvent. See Section 2425 in the service manual
to install the front eover and oil sear.
STEP 79

3412-21
and tighten to a
Torque the fan pulley bolts as ~:

Grade 8.8 Bolts ........ 18 lb ft 24 Nm (2.4 kgm)
Grade 10.9 Bolts ....• ~ . 25 lb ft 34 Nm (3:4 kgm)
TIMING LOCK PIN

Removal
Remove the retaining ring from the lock pin hous- Remove the tack pin from the housing.
ing.

Remove the o-ring from the lock pin.
Installation
RETAINING RING
Install the lock pin in the housing.
lnstaff a new ().:ring on the lock pin.
Install the retaining ring in the lock pin housing.

3412-23
FUEL SHUTOFF SOLENOID
6T-590 and 6T A-590 Engine
Removal and Disassembly
Loosen the fuel shutoff solenoid. Disassemble the fuel shutoff solenoid. Check the
plunger and solenoid for scoring.
Remove the fuel shutoff solenoid from the injec-

tion pump. Use a small wire to make sure the orifice in the
plunger is free of foreign material.
Assembly and Installation
Assemble the fuel shutoff solenoid. Install the fuel shutoff sotenoid and tighten to a
torque of 10 lb ft (15 Nm}(1.5 i<gm).
Rae 8-26141 Revised 3--85 Printed in U.S.A.

3412-24
6-590 Engine
Removal and Disassembly
Disassemble the fuel shutoff solenoid. Check the

plunger and solenoid for scoring.
Assembly and Installation
Assemble the fuel shutoff solenoid. Tight~ the fuel shutoff solenoid to a torque of 10
lb ft (15 Nm)(1.5 kgm).
lnstall.the fuel shutpff solenoid in .the iflie!Ctkm

pump.
Rac.,26141 ReviSed 3-85 Printed in U.S.A.

3412-25
PRIMER PUMP
Removal
STEP 104
Disconnect the fuel inlet line ·from the primer Remove the bolts that hold the primer pump to the
pump. engine block.
Aef00V41 the fitting and gaskets from the fuel inlet Remove the primer pump from the engine block.
line.
Remove the gasket from the primer pump.
Rae &-26141 Revised 3-86 Printed in U.SA

3412-26
Primer Pump Installation

0
Install the bolts' in the primer pump and install a

new gasket over the bolts. ·
Install the new gaskets and fitting on

Install the primer pump in the engine block. line.
Tighten the bolts that hold the primer pump to the

engine block. pump.
Rae 8~26141 Revised 3-85 Printed in U.S.A.

3412-27
Tighten the inlet fitting to a torque of 24 lb ft (32

Nm)(3.2 kgm).
Rae 8-26141 Revised 3-85 Prl"ted tn U.S.A.

3412-28
INJECTION PUMP. TIMING

6-590 Engine
Make sure the timing pin is engaged in thecam- Install the injection pump shaft into the drive gear.
shaft gear. Make sure the slot in the drive gear and the key on
the injection pump are aligned.
STEP 115
Install the three nuts and bracket bolt. Tighten the

nuts and bracket bolt a small amount.
If pump shaft is not in the locked ,

rotate the shaft clockwise until the slot in the drive
gear and the key on the shaft are aligned.

3412-29
Tighten the drive gear nut a small amount. Tighten the injection pump shaft nut to a torque of
48 lb ft (65 Nm)(6.5 kgm).
Loosen the lock bo1t on the Injection pump. Move

the slot washer on the lock bolt. Tighten the lock Remove the plug from the flywheel housing.
Pull the lock pin out of the camshaft gear.

3412-30
Tighten the Injection pump mounting nuts and the

bracket bolt to a torque of 18 lb ft (24 Nm)(2.4
kgm).
Install tne engine turn over tool, push in on the tock

pin and tum the engine over until the lock pin
engages into,..the camshaft gear.
Putt the lock pin out of the .camshaft gear.
Rotate the injection pump until the mark on the

injection pump flange and the mark on the front
housing are aligned.

3412-31
STEP 129
Connect and tighten the fuel inlet .fine.
STEP 132
'
Install the fuet inlet nne. Follow Step '157 through Step 161 to install the
injection lines and the front cover.

3412-32
6T·590 and 6TA·590 Engine
Make sure the timing pin Is engaged In the cam- I

shaft gear. shaft.
STEP 134
Install the pump into the drive gear. Make

sure the slot in the drive gear and the key on injec-
tion are aligned.
NOTE: If the pump shaft is not in the locked posi-

tion rotate the shaft clockwise until the slot in the
drive gear and the key on the shaft are aligned.
Loosen the pump shaft fock bolt.
nut and inlet bolt a smalt amount.
Rae 8-26141 Revised 3-85 Printed In U;S.A.

3412-33
Tighten the nut to a torque

kgm).
lnstalf the and tighten the lock bolt to a

torque of 22 lb ft (30 Nm}(3.0 kgm).
Remove the plug from the flywheel housing.

3412-34
the engine turn,over tool, push in on the lock

pin and turn the engine over unttl the lock pin Remove the plug from
engages into the ~mshaft gear. · pump.
>f ?',
Rae 8-26141 Revised 3-85 Printed In U.S.A.

3412-35
STEP 149
STEP 148 STEP 150
lnstaff · engine turn over tool, pushin on the lock

:the turn the thAIIthf!tAI pin and tum the engine clockwise until the lock pin
housing and tum the engine counterclockwise un- engages Into the camshaft gear. The dial indicator
til there is no movement in the dial indicator. should read 1.50 mm. If the reading is correct go to
Step 153.

3412-36
STEP 151
Loosen the bracket bolt and the. nuts that

hold the injection pump to the front cover.
STEP 152
tnstaU the injection pftig and tighten to a

torque of 17 lb ft (23 Nm)(2.3 t<qm). '·
NOTE: If 1.5o mm can not be reached go to Step

70 in this section. ·
Tighten
a
nuts to torque of 18 lb ft (24 Nm)(2.4 kgm).
Rae &-26141 Revised 3-85 Printed in U.S.~

3412-37
Connect and tighten injection lines to the injection Install the front cover.
pump.
Pull the lock pin out of the c,amshaft gear.

Connect and tighten the injection lines to the fuel
injectors.
Install the plug in the flywheel housing.
Install and tighten the injector line bracket.

Section
3413
FUEL INJECTORS
Written In Clear
And
SimP..Ie
English
Rae 8-26150 Printed tn U.S.A.

CASE CORPORATION October, 1984
3413-2
TABLE OF CONTENTS
SPECIFICATIONS ............................................................................... 3,4
SPECIAL TORQUES .•.............•.••..•..•..•'. ............•......•...•......................... 4
SPECIAL TOOLS ....•.•...•....••....•......•..•........•..........................•............. 5
GENERAL INFORMATION .......•..•..........•.....•..........•.•.......••..............•........ 6
OPERATING PROCED·URES ....••......... ·~ •... ·.......•••.............•......•.................... i
LOCATING BAD INJECTORS

Locating Bad Injectors at the Fuel Pump .......................................................... 8
Locating Bad Injectors at the Cylinder Head .................... ~ ................................. 8
REMOVING INJECTORS •......•....•...........•.....•••...••.........•..•.................... 9,10
INSTALLING INJECTORS ......•..•...••....•...•.•................•...•...................... 11,12
FUEL INJECTOR TESTER ..•....•....••..............•..•...•.•...•.............................. 13

Nozzle Tester Preparation .....••.•...•..•..•.•.....••.....•....•.............•................. 13
TESTING INJECTORS ..............•.........• : ....•..........•.•...•••......................... 14

Checking Opening Pressure .......•...•...........•.•.......•...•...•.......................... 14
Checking Seat Leakage ........•...•...•••.............................•........................ 15
Spray Pattern . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . 15
MAINTENANCE OF THE INJECTOR

Disassembly . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16,17
Cleaning and Inspection •...........................•.. , ..................................•..... 18
Assembly ...................•...........................•................................... 19-21
INJECTOR ADJUSTMENTS
' Adjusting Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Rae &-26150 Issued 1G-84 Printed in U.S.A.

3413..;3
WARNING
When testing or adjusting fuel injectors, do not place your hands or arms in front of the
injector nozzle.
A The fuel spray from an injector has sufficient pene-

trating p.ower to puncture the flesh and destroy tissue.
Should the fuel enter the blood stream, it may cause
blood poisoning.
When testing or adjusting fuel injectors, do not place yc)ur hands or arms In front of the
injector nozzle.
Wash .the injured part with boric acid solution, support the injured finger or hand with a
splint and sling so the injured part will remain absolutely at rest until a physician can
examine it.
SPECIFICATIONS
6T-590
Part Number Opening Pressure
Spray Number Spray

Robert Angle of Orifice
Bosch Case Orifices Size New Used
0432131800 J904197 155· 4 0.29 mm 3550 to 3200 to

Degrees 3670 PSI 3625 PSI
(24 476 to (22 063 to
25 303 kPa) 24 994 kPa)
(245 to (220 to
253 Bar) 250 Bar)
Reset to 3475 to 3625 PSI

(23 959 to 24 994 kPa)
(220 to 250 Bar)
When Opening Pressure
Falls Below 3200 PSI
(22 063 kPa)(220 Bar)
Rae 8-:26150 ' Issued 10-84 Printed in U.S.A.

3413-4
SPECIFICATIONS
6TA-590
-
Part Number Opening Pressure
Spray Number Spray

Robert Angle of Orifice
Bosch Case Orifices Size New Used
0432131881 J903383 155 4 0.28 mm 3190 to 3120 to

Degrees 3310 PSI 3260 PSI
(21 994 to (21 511 to
22 821 kPa) 22 476 kPa)
(220 to (215 to
253 Bar) 225 Bar)
Reset to 3190 to 3310 PSI

" (21 994 to 22 821 kPa)
(220 to 228 Bar)
When Opening Pressure
: FaUs Below 3'120 PSI
(21 511 kPa)(215 Bar)
U.S.,Value Metric Value

Valve Leakage Rate ......•...................... No Leakage Permissible
Slight Moistening of Nozzle Tip Permissible
Maximum Opening pressure Variation

Between Each Cylinder ......................................... 150 PSI 1034 kPa
with Set of Injectors (10.34 Bar)
SPECIAL TORQUES
Injector Retaining Nut ........................................... 44 lb ft 60Nm
(6.0 kgm)
Leak Off Bolt ................•........•...................••..•... 6 lb ft 8Nm

(0.8 kgm)
Nozzle Cap Nut .........•......••.............•.•....•.......... 18 lb ft 24Nm

(2.4 kgm)
Issued 11H34 Printed rn:u.s.A.

3413-5
SPECIAL TOOLS
TORQUE WRENCH LB FT
TORQUE WRENCH INCH POUND
MAGNIFYING GLASS CAS-1066A WRENCH

66-0135
CAS-1357
COMPRESSION SPRING TESTER CAS-1694 ORIFICE
INJECTION BORE CLEANING WIRES
CLEANING TOOL
Rae 8-26150 Issued 1Q-84 Printed in U.S.A.

3413-6
GENERAL INFORMATION
The fuel injectors are in the cylinder head. There is INJECTOR VALVE- The valve controls the flow of
one injector for each cylinder. The fuel injector the fuel from the injector.
sends a measured amount of fuel to the combus-
tion chamber from the injection pump. Each quan- VALVE TOP- The valve stop has two dowel pins
tity of fuel must be sent to the combustion cham- which hold the valve tip to the body. This will make
ber in the form of fine particles. This will make sure a spray pattern that is correct Both faces of the
that there is complete combustion and efficient valve stop have a fine surface finish. The valve stop
engine performance. controls the distance that the valve will move.
IMPORTANT: The Injector tip end and the injector
valve are a matched assembly. The two parts are OPENING PRESSURE CONTROL SPRING -The
made smooth to fit together with accuracy. The spring controls the fuel pressure that is necessary
injector tip or the injector valve can not be replaced to lift the valve. from the seat.
separately for service. If it is necessary to replace
either the valve or tip, replace the complete tip SHIMS -The shims push down on the spring to
assembly. keep a given pressure on the valve.
IMPORTANT: Do not mix tip assemblies and bod- INJECTOR TIP- The valve and the valve seat are in
ies while the injectors are being disassembled. the injector tip. There are orifices in the injector tip
that atomize the fuel for better combustion and
INJECTOR BODY - The body holds the injector separate the fuel spray to mix the fuel spray with
parts in the correct position in the cylinder head. air.
The body has a high pressure channel and a leak
off channel. The lower face of the body has a fin- NOZZLE SEAL - The seal is under the cap nut and
ished surface and has two holes in the surface for stops engine compression leakage.
locating dowel pins. ,
OPENING PRESSURE CONTROL SPRING
INJECTOR BODY CAP NUT

/INJECTOR TIP
LEAK OFF
LEAK OFF CHANNEL SPRING SEAT
VALVE STOP
Rae 8-26150 Issued 1()-84 Printed in U.S.A.

3413-7
OPERATING PROCEDURES
The operation of the injector is easy and positive. When the fuel delivery stops, the pressure against
the valve is decreased and the control spring im-
A measured quantity of fuel under high pressure mediately returns the valve to the seat. This re-
moves from the injection pump to the high pres- moves the danger of leakage, after the measured
sure channel in the injector body. The fuel then amount of fuel has been released. The valve opens
moves through the valve stop channel and enters and closes very rapidly with a very clear noise.
the pressure chamber Which is around the valve in
the injector tip. A small amount of fuel leaks, during injection,
through the controlled clearance between the tip
When the pressure of the fuel against the valve is assembly and the injector body. This leakage adds
more than the set spring orifice, the valve is moved lubrication to all the moving parts in the injector.
from the seat. This permits the fuel under high This fuel then moves through the leak off channel,
pressure to enter the injector tip. The fuel then leak off lines and returns to the fuel tank.
moves through the spray orifices and to the com-
bustion chamber. The fuel reaches the combus-
tion chamber in an atomized condition.
VALVE STOP CHANNEL
LEAK OFF LEAK OFF CHANNEL

OPENtNG PRESSURE CONTROL SPRING PRESSURE CHAMBER
/
Rae 8-26150 Issued 1()..84 Printed in U.S.A.
3413-8
LOCA~ING BAD INJECTORS

If there is a loss of power during engine operation, STEP2
the injectors can be bad. Do the following proce-
dure to find the bad injectors.
Locating Bad Injectors

at the Fuel Pump
1. Loosen the tube nut on the fuel line. This will

release the fuel and the injector will not work. If
this injector is bad, there will not be any differ-
ence in the engine performance. Connect and
tighten the tube nut on the fuel line.
2. Do this procedure again for the remainder of the

injectors.
Case 6T-590 engirre.
Locating Bad Injectors

at the Cylinder Head
STEP3
1. Loosen the tube nut on the foel inlet line for the
injector at the cylinder head. If the injector is
bad, there will not'be any difference in the en-
gine performance. Connect and tighten the tube
nut a small amount on the fuel inlet line.
2. Do this procedure again for the remainder of the

injectors.
Rae 8-26150 Issued 10-84 Printed in U.S.A. -

REMOVING INJECTORS
Clean the lOcation around the fuel injectors. Disconnect the ' ne from the i and in-
stall a dust cover over the inlet of the injector.
Remove the leak off boU.
Loosen the fuellirie t~be nut.

Remove the leak off line gasket.
Rae 8-26150 Issued 1D-84 Printed in U.S.A.

3413-10
STEP 10 STEP 11
Remove the fu~l fnjector from the engit'l~.
IM~ORT~NT: Make sure that the injector sealing

gasket comes out with the injector. Use an accep-
table tool or wire to remove the sealing gasket from
the engine bore.
Install special toof and . . on the flat

surf~ of the injecter. loosen. the injector.
tMPOilTANf: Do not let the irljector.body rotate

when loosening. If the injector body does rotate it
will damage the cylinder head bore.
Always replace the h1jector sealing gasket when. a

fuel injector is remove(t Remove the remainder df
the injectors using the same pr'Qcedure.
Rae 8-26150 Issued 1o-84 Printed in U.S.A.

3413-11
INSTALLING INJECTORS
Install an injector bore cleaning tool. Turn the tool Install the injector in the cylinder head bore. The
clo'ckwise. Use a ratchet wrench. Clean the bore ball in the injector must align with the slot in the
with air under pressure or turn the .engine over to cylinder head bore.
remove the particles.
STEP 14
Tighten the . ··. retaining nut to a torque of 44

Install a new sealing gasket on the injector. Put a lb ft (60 Nm)'(6.0 kgm).
smaU amount of white greas~ or light oil on the
gasket to keep the gasket in position.
STEP 17
IMPORTANTi Do not add lubrication to the com-
plete nozzle assembly or nozzle bore. The lubrica-
tion will become hard during operation of the en-
gine. The injector will be eJifficu/t to remove from
the cylinder head. ·
NOTE: ·Make sure the top of the gasket does not

touch the leak off line.
Rae 8-26150 Issued 1()-84 PriAted in U.S.A.

3413-12
STEP 20
Rer:d~·.·
the iqj~tion
pump.
Rae 8-26150 ISSUed 11)-84 Printed in U.S.A.

3413-13
FUEL INJECTOR TESTER

Fuel injectors must be checked on the tester when
making the following service operations:
1. An injector that has been removed from the

engine for cleaning, must be checked on the
tester before the injector can be installed in the
engine.
2. A new injector assembly must be checked on the

tester before the injector can installed in the
engine.
3. All the injectors must be removed and checked

on the tester during an engine overhaul.
A Diesel Fuel Injection No~~letester (CAB-10249)
isneeded for checking and adjuStl!1Q the injectors..
4. An injector must be removed and checked on the
The following ;n8tructions will work for all mqdels
tester before the injector is disassembled, if the
of testers except for descriptions on adjustments
injector is the cause of engine performance that
to the te.ster. Operating instructions are given with
is not acceptable.
the tester.
The tester is used to make the fotlowing checks:
1. Check and adjust the injector opening pressure.
2. Check the injector assembly for fuel leakage.
3. Check the injector for accurate spray pattern.
Nozzle Tester Preparation

1. Fill the reservoir with clean fuet. 4. To remove the air that is in the system, close the
pressure release valve and the gauge protection
2. Connect the correct connectors to the .connec- vaJve, open the pump valve. Operate the pump
tion tube. rapidly to remove the air from the system.
3. Connect the injector to the tester.

3413-14
TESTING INJECTORS
The injector must be cleaned before testing the
injector. Wash the body, nozzle tip and the cap nut
in a solvent to remove. external dirt, grease and
carbon deposits from the cap, body and outside
diameter of the tip.
IMPORTANT: Do not perm;t the wire brush to

contact the tip (spray hole area) of the nozzle.
Connect the injectc;>r to the nozzle tester, The noz-

zle tip must b~. down. Use adapter elbow (Part
Number Y900-3), ,~traignt'adapter {Part Number
Y900-5) and adapter nut (Part Number Y900-6) .
.(,F
A WARNING When testing or adjusting

fuel Injectors, do not place your hands
or arn1s in front of the injector nozzie.
Fuel from the spray orifices can enter clothing and

skin, causing serious damage. The tip must always
be put in a recptacle to hold the spray.
Checking Opening Pressure

Close the pressure release valve and the gauge If the injectors do not meet the given opening pres-
protection val.ve, operate the pump rapidly to flush sure:
the injector. open the gauge protection valve and 1. New injectors can be adjusted to the given open-
raise the pressure slowly. until the injector valve ing pressures See Page 20.
opens (the gauge reading will fall quickly at this
point). Check the opening pressure against the 2. Injectors in use must be disassembled and
specifications: cleaned. See Page 16.
NOTE: There must not be more then 150 PSI (1034 3. Check for broken or weak opening pressure
kPa)(10.34 bar) difference between any of the in- control springs.
jectors that have b,een removed from the engine.
Rae 8-26100 Issued 1G-84 Printed in U.S;A.

3413-15
Checking Seat Leakage

Close the pressure release valve and the gauge 4. Open the pressure release valve and remove the
protection valve. Open the pump valve and operate injector.
the pump rapidly to flush the injector.
The following procedure must be followed if drops
1. Dry the injector tip completely. Open the gauge of fuel are seen on the nozzle tip.
protection valve.
1. Disassemble and clean the injector, see Pages
2. Lift the pressure at the injector to 100 PSI (690 16 through 18.
kPa)(6.9 bar) under the opening pressure.
2. Injector assembly, see Pages 19 through 22.
3. Close the pump valve for five seconds and check
the nozzle tip (spray hole location. The nozzle
leaks if drops of fuel are seen on the nozzle tip. A
small amount of moisture on the nozzle Up is
permitted.
Spray Pattern
Close the pressure release valve and the· gauge The injector will make a very clear noise when the
protection valve. Open the pump valve and operate test stand is operated rapidly. This noise will not
the tester at 60 strokes a minute, check the spray necessarily occur in the operation of the injector in
pattern. The nozzle must have a spray pattern that the engine. The noise is an indication of good seat
wiN atomize the fuel. The nozzle must not have a width and interference angles. This noise can
solid spray pattern. change between nozzles. The noise in the nozzles
must not be compared for purpose of making
nozzles acceptable of not acceptable.
If this injector makes a solid type spray pattern, do

this:
1. Check. the orifices that are not open and check

orifices for scratches and heavy damage.
2. Disassemble and clean the injector.
3. Check for pitting of the valve seat, wear of valve

interference angles, bent valves and distortion
in the body. Replace the complete injector as-
sembly if there is distortion in the body. Under
other conditions, replace the tip assembly only.
SOLID TYPE $PRAY PATTERN
RacB-26150 Issued 10.84 Printed in U.S.A.

3413-16
MAINTENANCE OF THE INJECTOR

Disassembly
STEP 23
This is a 17 millimeter injector. NOTE: Wet the nozzle and the holder assembly in
a cleaning solution that will remove carbon. Use
Gunk, Bende's Kleaner or a solution that is the
STEP 22 same as these. The cleaning solution will give as-
sistance to free the cap nut.
Use a small amount of force to turn the cap nut.

Check the nozzle when there is a small amount of
movement. Look to see if the nozzle turns with the
cap nut. If the nozzle turns with the cap nut, see
below.
IMPORTANT: The nozzle is being held in position

with the cap nut. If the nozzle turns with the cap
nut, carbon deposits between the two parts will
cause this. Do not loose the cap nut. This will
ca1.1se damage to the .dow&l pins, valve stop and
hOlder body pressure face. Wet .the nozzlfJ and the
holder assembly in a cleaner ~elution that removes
carbon, until the nozzle is frfJe in the cap nut. Re-
place the valve stop assembly it there is damage to
the .dowel pfns or valve stop.
Put the injector in a soft face vise with the two flat
surfaces toward the vise face. The tip of the injec-
tor must be up. Remove the sealing gasket.

3413-17
STEP 24
Loosen and remove the nozzle cap nut. . Remove the pressure spring seat.
NOTE: The injector parts have tight tolerances.

Dirt will damage a smooth surface. Keep the work STEP 28
location and tools clean. Disassemble and assem-
ble all parts carefully to prevent damage.
STEP 26
Remove the pressure adjusting shims.
Remove the vatve stop assembly.
Rae 8·261:l0 Issued 10-84 Printed in U.S.A.

3413-18
Cleaning and Inspection

1. All parts must be put in a solvent to loosen the
carbon deposits.
2. A brass wire brush must be used to clean the

outside of the tip body. Use cleaning wires to
remove the carbon from the spray orifices. Use
cleaning wires that are 0.0005 inches to 0.001
inches (0.0127 to 0.0254 mm) smaller in diame-
ter than the spray hole. Put the cleaning wire in
a pin vise (66-0021). The end of the wire must
extend 1/32 inch (0.79 mm) past the tip of the
pin vise. A longer length of wire will hit the
opposite wall of the sac hole and will break.
4. Clean all channels with air under pressure. Di-
rect the air through both ent:Js of the nozzle tip
assembly. Carbon deposits must be removed.
ORIFICE
CLEANING WIRES
(66-0036)
5. Make sure that the nonte valVe slides freely in

the nozzle body.
6. Carefully clean the nozzle valve and the inside

diameter of the body to remove all dirt, varnish
3. Use a stone to remove sharp edg~ from the end and other foreign deposits.
of the wire. A small flat Ofil one side of the wire
wilt ~ Jl ~ler tq dut the carbor~ from the 7. The injector valve must be Cleaned with a brush
orifice. ~ tt1e Cleaning wire in the spray orifice to remove depoSits from the seat location. Var-
ancl tumtn~ w~re trntUtbe wire is free. Wash the nish m~ be removed w~th a solvent and a
body with clealtsotventind look at the tip. The cteani ng pad made of felt. Do not put the valve in
nozzle tip must be ~placed if the otiifice in the tip a motor driven lathe to clean the valve. This
shows damage at the.edges. Damage to the ori- method can remove too.much .material from the
fice will change the spr~~tY pattern. valve which can change valve Uft. Look at the
valve for pitting or damage which can cause
NOTE: Use a glass (66-0136) that makes objects leakage.
look larger, to look at the tip.
8. Replace all parts that show damage. ··
Rae 8--26150 Issued 10-84 PrintEid in U.S.A.

3413-19
Assembly
GASKET
LEAK OFF BOLT
~
NOZZLE HOLDER c::J
SHIM AS
~®
NEEDED~
AAESWRE _,/I /
/
®
I
\../
/
,.,.,..""' ~
NOZZLE SEALING GASKET
SPRING SEAT
STEP 30 STEP 31
Install the pressure adlusting shims that are Install the pressure spring in the nozzle holder.
needed to set the opening pressure.
NOTE: Clean all parts in clean diesel fuel before
assembly.
Rae. 8-26150 Issued 1Q-84 Printed In U.S.A.

3413-20
STEP 32 STEP 35
Install the spring seat on the pressure spring. The Align the dowef pin holes in the no~le tip assem-
small diameter end of the. spring seat must be to- bly with the dowel pins in the stop valve assembly.
ward the pressure spring. Install the no:z:zle tip assembly on the valve stop
assembly.
STEP 33
STEP 36
Install the valve stop assembly. Align the dowel

pins that are in the valve stop with the dowel pin Add lubrication to the nozzle shoulder. Do not put
holes that are in the no~le holder. grease on the holder or the threads of the cap nut.
Install the cap nut over the end of the nozzle tip
assembly and turn the cap nut ctockwise two or
three times.
Put a small amount of clean fuel on the n<>Uie valve

and slide the nozzle valve up and down a number of
times in the no:zzle tip to make sure that there is
free movement
Rae 8-26150 Issued 1o-84 Printed.in U.S.A.

3413-21
STEP 37
Put the injector in a soft face vise with the tip of the Check the fuel injector on the test stand.
injector up. The flat surface of the injector must be
toward the face of the vise. Tighten the cap nut to a
torque 9f 18 lb ft {24 Nm){2.4 kgm).
PRESSURE SPRING
NOZZLE TIP
ASSEMBLY
DOWEL PIN CAP NUT
Rae 8-26150 Issued 1G-84 Printed in U.S.A.

3413-22
INJECTOR ADJUSTMENTS
Adjusting the Opening Pressure

STEP 39 STEP 41
Remove the fuel injector from the nozzle tester. Put Assemble the fuel injector. See Pages 19 through
the injector in a soft face vise. The flats of the 21.
injector holder must be toward the face of the vise.
The injector tip must be up. Loosen the cap nut. To
disassemble the injector see Pages 16 and 17. STEP 42
STEP 40
Check again the opening pressure of the fuel injec-

tor on the nozzle tester. Repeat Steps 39 through
41 on this page, as necessary, until the needed
Add pressure adjusting shims to increase the opening is correct.
opening pressure. Remove p(essure adjusting
shims to decrease opening pressure Do this until
the correct pressure is reached.
IMPORTANT: The opening pressure is changed

by about 55 PSI (379 kPa)(3. 79 bar) for each 0.001
inch (0.254 mm) of shim thickness that is added or
removed.

4001
REMOVAL AND INSTALLATION
OF ELECTRICAL COMPONENTS
TABLE OF CONTENTS
Starter ....................................................................................... 4001-2
Alternator .................................................................................... 4001-3
Written In Clear
And
Simple
English

4001-2
STARTER
Removal Installation
1. Park the machine on a level surface and apply 1. Put the starter in position on the flywheel
the parking brake. housing.
2. If the machine has a dozer, lower the dozer to 2. Install the cap screws and flat washers that
the ground. If the machine has a loader, raise the fasten the starter to the flywheel housing.
loader and install the support strut.
3. Connect the wires and the cable to the termi-
3. Stop the engine. nals on the starter solenoid.
4. Put the master disconnect switch in the OFF 4. Put the master disconnect switch in the ON
position. position.
5. Remove the right side panel for the engine 5. Install the right side panel.
I
compartment.
6. If the machine has a loader, do the following:
6. Fasten identification tags on the wires and ca-
ble connected to the terminals on the starter sole- a. Start the engine.
noid.
b. Raise the loader and install the support
7. Disconnect the wires and cable from the termi- strut in the storage position.
nals on the starter solenoid.
c. Lower the loader and stop the engine.
8. Hold the starter and remove the three cap
screws and flat washers that fasten the starter to
the flywheel housing.
9. Remove the starter.

4001-3
ALTERNATOR
Removal 12. Hold the alternator and remove the cap screw
at the top of the alternator.
1. Park the machine on a level surface and apply
the parking brake. 13. Remove the alternator.
2. If the machine has a dozer, lower the dozer to Installation

the floor. If the machine has a loader, raise the
loader and install the support strut. 1. Hold the alternator in alignment with the
mounting bracket and install the cap' screw at the
3. Stop the engine. top of the alternator. Do not tighten the cap screw.
4. Put the master disconnect switch in the OFF 2. Install the cap screw that fastens the mounting
position. link to the bottom of the alternator.
5. Remove the right side panel for the engine 3. Tighten the cap screw at the top of the alterna-
compartment. tor.
6. Hold the belt tightener out of the way and re- 4. Install the plug for the wiring harness.
move the drive belt from the pulley.
5. Install the wires on the BAT terminal.
7. Remove the cover from the BAT terminal of the
alternator. 6. Install the lock washer and nut on the BATter-
minal.
8. Remove the nut and lock washer from the BAT
terminal. 7. Install the cover on the BAT terminal.
9. Remove the wires from the BAT terminal. 8. Hold the belt tightener out of the way and in-
stall the drive belt on the pulley.
10. Remove the plug for the wiring harness from
the alternator. 9. Install the right side panel.
11. Remove the cap screw that fastens the mount-

ing link to the bottom of the alternator.
4002
ELECTRICAL SYSTEM SPECIFICATIONS
AND TROUBLESHOOTING
TABLE OF CONTENTS
Specifications ................................................... 4002-2 Troubleshooting the Bosch Charging

Circuit ............................................................ 4002-9
Troubleshooting Chart ..................................... 4002-3
General Inspection ........................................ 4002-9
Batteries ......................................................... 4002-3
Checking Voltage at the Alternator
Alternator ....................................................... 4002-4 Terminals .................................................... 4002-9
Starter ............................................................ 4002-5 Alternator and Voltage Regulator Test.. ...... 4002-10
Troubleshooting the Delco-Remy Charging Troubleshooting the Starting Circuit.. ........... 4002-12
Circuit ............................................................ 4002-6
General Inspection ...................................... 4002-12
General Inspection ........................................ 4002-6
Starter and Solenoid Test ............................ 4002-12
Checking Voltage at the Alternator
Terminals .................................................... 4002-6 Troubleshooting the Return-to-Dig
Control ......................................................... 4002-14
Alternator and Voltage Regulator Test.. ........ 4002-7
Magnetic Detent Will Not Release the
Control Lever ............................................ 4002-14
Magnetic Detent Will Not Hold the Control

Lever ........................................................ 4002-15

4002-2
SPECIFICATIONS
Type of system ............................................................... 24 volt, negative ground
System voltage ................................................................ Approximately 24 volts
Batteries .................................................... Two 12 volt batteries, connected in series
Minimum output of alternator

Delco-Remy ........................................................................................................................36 amps at 25 to 29 volts
Bosch ..................................................................................................................................40 amps at 25 to 29 volts
Starter ..................................................................... 24 volt, solenoid actuated
Circuit breakers for complete system ................................ 80 amperes, two 40 ampere circuit
breakers connected in series
Circuit breaker for lamp switch, fuel shutoff switch,

pressure switch, and miscellaneous accessories ........................................... 25 ampere
Circuit breaker for cab ..................................................................... 40 ampere
Front lamp ................................................................................. No. 4589
Rear lamp .................................................................................. No. 4589
Bulb for instrument panel lamp ............................................................... No. 623
Bulb for cab lamp ........................................................................... No. 1591
Fuse for blower motor ............................................................... 3AG8, 8 ampere
Fuse for front windshield wiper and cab lamp .......................................... 3AG3, 3 ampere
Fuse for rear windshield wiper ........................................................ 3AG3, 3 ampere

4002-3
TROUBLESHOOTING CHART
Battery(ies)
PROBLEM POSSIBLE CAUSE CORRECTION
Discharged Low electrolyte level in battery(ies). See Electrolyte Level in Section 4005.
battery(ies).
Dirty battery top. See Maintenance in Section 4005.
Loose or dirty connections for Clean clamps on battery cables and

battery cables. clean battery posts.
Damaged battery cell or cells. Do Capacity (Load) Test in Section 4005.
Low or no output from alternator. Do Troubleshooting the Charging Circuit

in this section.
Battery needs water Battery malfunction. Do Battery Tests in Section 4005.

frequently.
Bad wire connections between Clean and tighten connections.
alternator and battery.
Bad voltage regulator. Do the Alternator and Voltage Regulator

Test in this section.
4002-4
Alternator
Noise coming from Damaged or worn drive belt. Install a new drive belt.
the alternator.
Damaged or loose pulley on the Remove the pulley and check for
alternator. damage to the rotor shaft and pulley.
Install new parts as necessary. Tighten
nut to specification in Section 4007.
Worn or damaged bearings in the Disassemble the alternator and

alternator. replace the bearings as necessary. See
Section 4007.
Short circuit in the rectifier diodes. Disassemble the alternator and do the
diode tests in Section 4007.
Short circuit in the stator. Look for burned insulation on the

stator coils. Also, do the stator tests
in Section 4007.
Ammeter shows a Bad voltage regulator. Do the Alternator and Voltage Regulator
high charging rate Test in this section.
at all times.
Bad connection, wires, or other parts See the electrical schematics in Section
in the charging circuit. 4003 and make repairs as necessary.
Bad ammeter. See Section 4004.
Ammeter shows a Damaged drive belt. Replace the drive belt.

low charging rate
or no charge. Bad regulator or alternator. Do the Alternator and Voltage Regulator
Test in this section.
Bad connections, wires or other See the electrical schematic in Section

parts in the charging circuit. 4003 and make repairs as necessary.
Bad ammeter. See Section 4004.

4002-5
Starter
Starter runs slowly. Discharged battery( ies). See Troubleshooting Chart for
Battery(ies).
Loose ground cable at starter or Clean and tighten connections.

frame.
Loose or dirty connections for Clean clamp on battery cables and

battery cables. clean the battery posts.
Loose cap screws that hold starter Tighten cap screws.

to flywheel housing.
Using wrong engine oil for cold See Fluids and Lubricants Chart in
weather operation. Section 1002.
Worn or damaged starter. Do the No Load Test for the starter.

See Section 4006.
Obstruction in exhaust system. Check exhaust system for obstruction.
Damaged hydraulic pump. See Section 8005. Remove and inspect

hydraulic pump.
Starter does not run Master disconnect switch in the OFF Move the master disconnect switch to the
position. ONposition.
Loose ground cable at starter or Clean and tighten connection.

frame.
Loose or dirty connections for Clean clamp on battery cables and

battery cables. clean the battery posts.
Bad connections, wires, or other See the electrical schematic in Section

parts in the starting circuit. 4003 and make repairs as necessary.
Bad master disconnect switch. Install a new master disconnect switch.
Bad start switch. Install a new start switch.
Damaged starter solenoid. Do the Starter Solenoid Test in

Section 4006.
Damaged starter. Do the No Load Test in Section 4006.

4002-6
TROUBLESHOOTING THE DELCO-REMY CHARGING CIRCUIT

General Inspection
1. Check the condition of the batteries according
to the instructions in Section 4005.
2. Clean the battery posts and the connectors on

the battery cables.
3. Make sure the connections in the charging cir-

cuit are clean and tight. See Section 4003 for the
electrical schematic.
4. Make sure there is no oil or grease on the alter-

nator drive belt and the alternator drive belt is tight.
5. If the alternator still does not operate correctly,

do the following test.
Checking Voltage at the

Alternator Terminals
Use a voltmeter to check the voltage at the 850758
alternator terminals.
1. BAT Terminal
1. Do the General Inspection procedure above. 2. No. 1 Terminal
3. No. 2 Terminal
2. Put the fuel shutoff switch in the OFF position. 4. Test Hole
3. Put the master disconnect switch in the ON

position. a. If the voltmeter indicates system voltage,
do step 5.
4. Connect the negative voltmeter lead to the
housing of the alternator. Connect the positive b. If the voltmeter does not indicate system
voltmeter lead to the BAT terminal of the alternator. voltage, use the voltmeter to check the charg-
ing circuit. Be sure to check the operation of
the master disconnect switch. See Section
4003 for the electrical schematic.
5. Disconnect the connector from the alternator.

housing of the alternator. Connect the positive
voltmeter lead to the terminal in the connector that
was connected to the No.2 terminal in the alterna-
tor.
a. If the voltmeter indication is system volt-

age, do step 7.
b. If the voltmeter does not indicate system

voltage, replace the wire that connects the
connector to the BAT terminal of the alternator.
4002-7
7. Connect the negative voltmeter lead to the c. Select the ampere range that will measure
housing of the alternator. Connect the positive 100 amperes.
voltmeter lead to the other terminal in the connec-
tor that is connected to a wire. Start the engine and d. Put the volt lead selector in the EXT. posi-
read the voltmeter. Stop the engine. Connect the tion.
connector to the alternator.
6. Connect the tester to the batteries as follows:
a. If the voltmeter indication was within one
volt of system voltage, do the Alternator and
Voltage Regulator Test in this section.
b. If the voltmeter does not indicate a voltage

within one volt of system voltage, use the volt-
meter to check the charging circuit. See Sec-
tion 4003 for the electrical schematic.
Alternator and Voltage

Regulator Test
The test can be done using a tester for the 5 1' - - - - - . . . 1
starting and charging systems, such as the Sun
Electric VAT-33. Other test equipment can be used.
Connect the test equipment according to the in- 850759
structions of the manufacturer of the equipment.
1. 12 Volt Battery
2. Positive Battery Cable
3. Jumper Cable
4. Negative Battery Cable
5. To Master Disconnect Switch
6. Negative Load Lead of Tester
7. Negative Voltmeter Lead of Tester
B. Positive Load Lead of Tester
9. Positive Voltmeter Lead of Tester
10. Ammeter Clamp
a. Connect the negative load lead of the tes-

ter to the negative battery post of the battery
795328 that is connected to the master disconnect
switch.
1. Apply the parking brake. b. Connect the negative voltmeter lead of the
tester to the same negative battery post.
2. Do the General Inspection procedure on page
4002-6. c. Connect the positive load lead of the tester
to the positive battery post of the same battery.
3. Make sure the fuel shutoff switch is in the OFF
position. d. Connect the positive voltmeter lead of the
tester to the positive battery post of the other
4. Make sure the master disconnect switch is in battery.
the ON position.
e. Fasten the ammeter clamp of the tester
5. Adjust the controls for the tester as follows: around the negative battery cable. The point of
the arrow on the ammeter clamp must be to-
a. Move the load control to the OFF position. ward the battery.
b. Select the volt range that will measure 24 7. Start the engine and run the engine at 1/2 throt-
volts. tle.
4002-8
8. Adjust the load control of the tester to get the 13. Have another person hold a screwdriver in the
maximum ammeter indication. Read the ammeter test hole in the rear housing of the alternator. There
and the voltmeter. Make a record of the ammeter is a tab behind the test hole. Hold the screwdriver in
and the voltmeter indications. contact with the tab and the rear housing.
NOTE: Do not apply a load to the battery for more

than 15 seconds at one time. After 15 seconds turn
the load control to the OFF position for 60 seconds
before applying the load again.
9. Turn the load control to the OFF position.
10. Decrease the engine speed and stop the en-

gine.
11. The ammeter indication in step 8 must not be

less than 36 amperes and the voltmeter indication
in step 8 must be 25 to 29 volts.
a. If the ammeter and the voltmeter indica-

tions were correct, the alternator and the volt-
14. Keep the screwdriver in the test hole and ad-
age regulator are good.
just the load control of the tester to get the maxi-
mum ammeter indication. Read the ammeter.
b. If the ammeter and the voltmeter indica-
tions were not correct, do the remainder of the
NOTE: Do not apply a load to the battery for more
test.
than 15 seconds at one time. After 15 sec-onds turn
the load control to the OFF position for 60 seconds
12. Startthe engine and run the engine at 1/2 throt-
before applying the load again.
tle.

gine.
17. If the ammeter indication was:
a. 36 or more amperes, remove the alternator

and replace the voltage regulator. Before as-
sembling the alternator, do the rotor test ac-
cording to the instructions in Section 4002. A
damaged rotor will damage a new voltage reg-
ulator.
b. Less than 36 amperes, see Section 4007

and disassemble the alternator and check the
components.
4002-9
TROUBLESHOOTING THE BOSCH CHARGING CIRCUIT

General Inspection 4. Connect the positive voltmeter lead to the B+
terminal of the alternator. Connect the negative
1. Park the machine on a level surface and lower voltmeter lead to a good ground connection on the
the attachments to the floor. engine.
2. Apply the parking brake and stop the engine.
3. Make sure all of the controls are in the NEUTRAL

position.
4. Check the condition of the batteries according

to the instructions in Section 4005.

the battery cables.
6. Make sure the connections in the charging cir-

cuit are tight. See the electrical schematic in the
pocket inside the rear cover of this service manual.
7. Make sure there is no oil or grease on the alter-

nator drive belt and the alternator drive belt is tight.
8. If the alternator still does not operate correctly,

do the following check. ~.:--- 2. D+ TERMINAL
~-- 1. 8+ TERMINAL
Checking Voltage at the
Alternator Terminals
8901399
Use a voltmeter for this test.
1. Do the General Inspection procedure above.

a. If the voltmeter indicates system voltage,
2. Put the engine run switch in the ON position. do step 6.
3. Put the master disconnect switch in the ON b. If the voltmeter does not indicate system
position. voltage, do step 5.
5. Connect the positive voltmeter lead to battery

terminal of the starter solenoid. See the illustration
on page 4002-00 for the location of the battery
terminal. Connect the negative voltmeter lead to a
good ground connection on the engine.
a. If the voltmeter indication is system volt-

age, do step 6.
b. If the voltmeter does not indicate system

voltage, use the voltmeter to check the charg-
ing circuit between the alternator and the star-
ter. See Section 4003 for the electrical
schematic.
4002-10
6. Disconnect the connector from the D+ termi- 1. Do the General Inspection procedure on page
nal of the alternator. 4002-8.
7. Connect the positive voltmeter lead to the ter- 2. Do Checking Voltage at the Alternator Termi-
minal in the connector. Connect the negative volt- nals on page 4002-8.
meter lead to a good ground connection on the
engine. Start the engine and read the voltmeter. 3. Make sure the parking brake is applied.
Stop the engine.
4. Make sure the master disconnect switch is in
a. If the voltmeter indicated system voltage, the ON position.
connect the connector and do the Alternator
and Voltage Regulator Test in this section. 5. Adjust the controls for the lester as follows:
b. If the voltmeter did not indicate system a. Move the load control to the OFF position.
voltage, do step 8.
b. Select the volt range that will measure 24
8. Start the engine and look at the hourmeter to volts.
see if the hourmeter is running. Stop the engine.
c. Select the ampere range that will measure
a. If the hourmeter ran, the problem is in the 100 amperes.
wire between the connector at the alternator
and the engine pressure switch. See the elec- d. Put the volt lead selector in the EXT. posi-
trical schematic in.Section 4003 and repair or tion.
replace the wire.
6. Connect the tester to the batteries as follows:
b. If the hourmeter did not run, the problem is
in the circuit between the ammeter and the
engine pressure switch or the engine pressure
switch is bad. See the electrical schematic in
Section 4003 and use a voltmeter to check the
circuit. If the circuit is good, replace the engine
pressure switch.
Alternator and Voltage

Regulator Test
The test can be done using a tester for the
starting and charging systems, such as the Sun
Electric VAT-33. Other test equipment can be used.
5 1.....__ ___, 1 ..._ _____....
Connect the test equipment according to the
instructions of the manufacturer of the equipment. 850759
1. 12 Volt Battery
3. Jumper Cable
5. To Machine Frame
6. Negative Load Lead of Tester
7. Negative Voltmeter Lead of Tester
B. Positive Load Lead of Tester
9. Positive Voltmeter Lead of Tester
10. Ammeter Clamp
4002-11
a. Connect the negative load lead of the tes- NOTE: Do not apply a load to the battery for more
ter to the negative battery post of the battery than 15 seconds at one time. After 15 seconds turn
that is connected to the master disconnect the load control to the OFF position for 60 seconds
switch. before applying the load again.
b. Connect the negative voltmeter lead of the 9. Turn the load control to the OFF position.
tester to the same negative battery post.
c. Connect the positive load lead of the tester gine.
to the positive battery post of the same battery.
11. The ammeter indication in step 8 must not be
d. Connect the positive voltmeter lead of the less than 40 amperes and the voltmeter indication
tester to the positive battery post of the other in step 8 must be 25 to 29 volts.
battery.
a. If the ammeter and the voltmeter indica-
e. Fasten the ammeter clamp of the tester tions were correct, the alternator and the volt-
around the negative battery cable. The point of age regulator are good.
the arrow on the ammeter clamp must be to-
ward the battery. b. If the ammeter and the voltmeter indica-
tions were not correct, the problem is the sta-
7. Starttheengineand runtheengineat1/2throt- tor or the voltage regulator. See Section 4019
tle. and disassemble the alternator and check the
stator. If there is not a problem in the stator,
8. Adjust the load control of the tester to get the assemble the alternator and then replace the
maximum ammeter indication. Read the ammeter voltage regulator and brush assembly.
and the voltmeter. Make a record of the ammeter
and the voltmeter indications. NOTE: If a new voltage regulator and brush
assembly is available, replace the voltage reg-
ulator and brush assembly and repeat the test.
If the alternator still does not operate cor-
rectly, see Section 4019, disassemble the al-
ternator, and relace the stator.
4002-12
TROUBLESHOOTING THE STARTING CIRCUIT

General Inspection 6. Connect the positive voltmeter lead to the bat-
tery terminal on the starter solenoid. Connect the
1. Check the condition of the batteries according negative voltmeter lead to a good ground on the
to the instructions in Section 4005. machine.

the battery cables.
3. Check for loose connections and corrosion at

the connections on the starter, starter solenoid, 40
ampere circuit breaker, start switch, and ammeter
disconnect switch. See the wiring schematic in
Section 4003.
4. Check for damaged insulation and broken

wires in the starting circuit. Repair or replace any
damaged or broken wires. See the wiring schema-
tic in Section 4003.
1
5. If the starter still does not operate, do the fol-
lowing test.
Starter and Starter

Solenoid Test
1. Do the General Inspection procedure above.
2. Make sure the parking brake is applied.
3. Make sure all controls are in the NEUTRAL posi- 1. Battery Terminal
tion. 2. Switch Terminal
3. Motor Terminal
4. Make sure the fuel shutoff switch is in the OFF
position.
a. If the voltmeter does not indicate system
5. Make sure the master disconnect switch is in voltage, do step 7.
the ON position.
b. If the voltmeter indicates system voltage,
do step 8.
Continued on next page

4002-13
7. Connect the positive voltmeter lead to the pos- b. If the starter did not operate correctly, do
itive post of the rear battery. Keep the negative step 9.
voltmeter lead connected to a good ground on the
machine. 9. Momentarily connect a jumper wire between
the motor terminal and the battery terminal. Dur-
a. If the voltmeter indicates system voltage, ing this test the starter drive will not engage the
replace the positive battery cable and repeat flywheel.
the test.
a. If the starter ran, the starter solenoid is
b. If the voltmeter does not indicate system bad. Replace the starter solenoid.
voltage, check for a bad master disconnect
switch and bad ground cables. b. If the starter did not run, the starter is bad.
Repair or replace the starter.
8. Momentarily connect a jumper cable between
the battery terminal and the switch terminal on the
starter solenoid.
a. If the starter operated correctly, the starter

and the starter solenoid are good. Use a volt-
meter to check the starting circuit. See Section
4003 for the electrical schematic.
4002-14
TROUBLESHOOTING THE RETURN-TO-DIG CONTROL

4. If the magnetic detent still will not release the
control lever, lower the bucket to the floor.
5. Stop the engine.

the ON position.
7. Remove the access cover above the instru-

ment panel.
~5;,.___6 8. Connect a jumper wire to the two terminals of

the pressure switch.
850797
1. Limit Switch
2. Connector
3. Red Wire
4. White Wire
5. Black Wire
6. To Pressure Switch
7. Magnetic Detent 500008
Magnetic Detent Will Not

Release the Control Lever 9. Move the control lever to engage the magnetic
detent.
the parking brake. Lower the loader frame so that 10. Hold a 1-1/2 inch (38 mm) square piece of steel
the bucket is flat on the floor. against the end of the limit switch.
2. Check the position of the actuator bar. The a. If the magnetic detent releases the control
actuator bar must completely cover the limit switch. lever, replace the limit switch.
See Section 9010 for adjustment instructions.
b. If the magnetic detent still does not release
3. Check the air gap between the actuator bar and the control lever, do step 11.
the limit switch. The air gap must not be more than
5/16 inch (8 mm). Adjust the position of the limit 11. Disconnect the wiring at the limit switch.
switch as required and check the operation of the
magnetic detent. a. If the magnetic detent releases the control
lever, replace the limit switch.
b. If the magnetic detent still does not release

the control lever, do step 12.
12. Remove the cover from the right side of the

right console.
4002-15
13. Disconnect the connector at the magnetic de- 6. Install ajumperwiretothe two terminals of the
tent. pressure switch. See photo on page 4002-11.
a. If the magnetic detent releases the control 7. Disconnect the connector at the limit switch.
lever, do step 14.
8. Use a voltmeter to check for system voltage at
b. If the magnetic detent does not release the the two outer terminals of the connector on the
control lever, the centering spring in the valve wiring harness. Do not connect the voltmeter to the
is broken or the spool cannot move freely in the terminals in the connector on the limit switch.
valve. See Section 8007 and repair the valve as
necessary. a. If the voltmeter indicates system voltage at
both of the terminals, do step 9.
14. Put the master disconnect switch in the OFF
position. b. If the voltmeter does not indicate system
voltage at both of the terminals, do step 11.
15. Connect one lead of an ohmmeter to a good
ground connection on the machine frame. Con- 9. Put the master disconnect switch in the OFF
nect the other lead of the ohmmeter to first one position.
terminal and then the other terminal in the connec-
tor for the magnetic detent. 10. Use an ohmmeter to check for continuity be-
tween the machine frame and the middle terminal
a. If the pointer of the ohmmeter did not of the connector on the wiring harness.
move, there is a short circuit in the wiring har-
ness between the limit switch and the mag- a. If the pointer of the ohmmeter did not
netic detent. Repair or replace the wiring har- move, there is a problem in the ground circuit
ness. A short circuit will have damaged the of the wiring harness. Repair of replace the
limit switch. Replace the limit switch. wiring harness as necessary.
b. If the pointer of the ohmmeter moved, b. If the pointer of the ohmmeter moved, re-
there is a short circuit in the magnetic detent. place the limit switch.
Replace the magnetic detent. A short circuit
will have damaged the limit switch. Replace the 11. Put the master disconnect switch in the OF~
limit switch. position.
Magnetic Detent Will Not 12. Remove the cover from the right side of the
right console.
Hold the Control Lever
13. Disconnect the wiring harness from the mag-
netic detent.
the parking brake.
14. Use an ohmmeter to check for continuity be-
2. Lower the loader to the floor.
tween the two terminals in the connector for the
mag netic detent.
3. Put the key switch in the OFF position to stop
the engine. a. If the pointeroftheohmmeterdid no move,
replace the magnetic detent.
the ON position. b. If the pointer of the ohmmeter moved, the
problem is in the wiring harness. Repair or
5. Remove the access cover above the instru- replace the wiring harness as required.
ment panel.
4003
WIRING DIAGRAMS
TABLE OF CONTENTS
Canopy Wiring Diagram ....................................................................... 4003-2
Chassis Wiring Diagram ....................................................................... 4003-3
Cab Wiring Diagram .......................................................................... 4003-5
Written In Clear
And
Simple
English

CASE CORPORATION
4003-2
FRONT FLOOD
LAMP
~42 42 ---rn~--- ..
42
TO MAIN
HARNESS
o- ·
42 - - - 4 t - - - 42 -----..:.rn---- 42
lffl\\
~
REAR FLOOD
LAMP
42
_r·-rn-·
MACHINE ROPS
FRAME
REAR FLOOD
LAMP
FRONT FLOOD
----42-----(D--42~
LAMP
®-42
Wire Color Code 150482

0 Black
42 Dark Blue
Canopy Wiring Diagram

4003-3
SOLENOID VALVE THERMOCOUPLE

- - - - - - - 2 1 ---.
MASTER DISPQf\INECT
SWITCH
FUEL SHUTOFF FUEL SHUTOFF
r:::ETi7m\l__ SWITCH
~23-----+------T----..::.:...:..:...:....;::;.::.:_--,
1
35H--o-~ BACKUP ALARM
35H-1 HOURMETER j-ol
HORN
ry~ 21
40AMPERE
CIRCUIT BREAKER
AMMETER
0 CONNECTOR
40 AMPERE
....,.....____, CIRCUIT BREAKER
-- FOR CAB ONLY
MAGNETIC
l.:::~~_J DETENT
Wire Color Code
0 Black 21 White 35H Yellow
1 Red 23 White 42 Dark Blue
13 Orange 26 Light Blue 52 Gray 8500/8550
Common (Starting and Charging Circuit) 14F Light Green 28 Light Blue 64 Orange With Tracer
19 Light Green With White Tracer
Starting Circuit
Chassis Wiring Diagram 8-42190

4003-4
CAB ELECTRICAL COMPONENTS

A. Flood lamp N. Fuse for cab blower
B. Blowers for condenser 0. Fuse for rear windshield wiper
c. 80 ampere circuit breaker P. Resistor
D. 40 ampere circuit breaker Q. Blower motor
E. Supply wiring harness R. Cab lamp switch
F. Fuse and relay wiring harness s. Cab lamp
G. Air conditioner switch T. Rear windshield wiper
H. ROPS cab blower switch u. 15 ampere circuit breaker
I. Front windshield wiper switch v. Low pressure switch
J. Front windshield wiper w. Connected to high pressure switch
K. Switch wiring harness at compressor
L. Relay
M. Fuse for front windshield wiper and
cab lamp
CAB ELECTRICAL CIRCUITS

WIRE COLOR FROM TO
NO.
1. Red 40 ampere circuit breaker Relay

2. Purple BAT terminal, starter solenoid Relay
3. Dark blue H terminal lamp switch Flood lamps
4. Black Mounting bolt for restriction Ground connection in cab
indicator
5. Black Ground connection in cab Relay
6. Red Relay splice for wire No.7, 8, and 9
7. Red Splice to wire No.5 Fuse for rear windshield wiper
8. Red Splice to wire No.5 Fuse for cab blower motor
9. Red Splice to wire No.5 Fuse for front windshield wiper and
cab lamp
10. Light Green Fuse for front windshield wiper and B terminal, front windshield
cab lamp wiper
11. Black Front windshield wiper P terminal, front windshield wfper
switch
12. Red Front windshield wiper H terminal, front windshield wiper
switch
13. Green Front windshield wiper L terminal, front windshield wiper
switch
14. White H terminal, cab blower switch Plug for resistor
15. White H terminal, cab blower switch B terminal, cab blower switch
16. Brown M terminal, cab blower switch Plug for resistor
17. Orange L terminal, cab blower switch Plug for resistor
18. Red Fuse for rear windshield wiper Rear windshield wiper
19. Yellow Fuse for cab blower motor Red wire at cab blower motor
20. Light Green Fuse for front windshield wiper and Switch for cab lamp
cab lamp
21. Light Blue Cab blower switch Air conditioner switch
22. Light Blue Air conditioner switch 15 ampere circuit breaker
23. Red 15 ampere circuit breaker Low pressure switch
24. Light Blue 15 ampere circuit breaker Blower motors for condenser
8-42190
4003-5
~A~
~_j
....-------- 3
B
~-----------24--~~~============~~~
E
F
K
20
gl~----3
ooo
~
~--22---J
22 14 17
p 000
~M
'
19
18
a
@ @
.__r_ 3l
~~------· ......
=====A
~
Cab Wiring Diagram

4004
INDICATORS AND GAUGES
TABLE OF CONTENTS
Checking the Accuracy of the Gauges . . . 4004-2 Gauge for Torque Converter Oil
Temperature ....................... 4004-5
Ammeter ............................ 4004-2
Hydraulic Oil Temperature Gauge (For
Engine Oil Pressure Gauge ........... 4004-3 Machines with Backhoe) ............ 4004-6
Transmission Oil Pressure Gauge ..... 4004-3 Hourmeter ............................. 4004-6
Water Temperature Gauge ............ 4004-4 Illustrations of Indicators and Gauges . 4004-7 & 8
Written In Clear
And
Simple
English

4004-2
CHECKING THE ACCURACY OF THE GAUGES

Ammeter c. Select the amp. range that will measure 0
to 100 amperes.
The ammeter test can be done using a tester
for starting and charging systems, such as the Sun d. Put the volt select switch in the EXT. posi-
Electric VAT -33. tion.
5. Connect the black load lead to the negative

post of the battery.
1 6. Connect the red load lead to the positive post

of the battery.
7. Fasten the ammeter clamp around the positive

battery cable so the point of the arrow on the am-
meter clamp is toward the battery.
0
0 8. Put the tester in position so the tester can be
5 0
0 read from the seat for the operator.
o_
0
9. Turn the key switch to the OFF position.
10. Push in and hold the starter button for 30 sec-

onds, then release the starter button. Do not hold
7 the starter button longer than 30 seconds.
1. Ammeter 11. Wait for three minutes for the starter motor to
2. Ammeter Clamp become cool.
3. Negative Load Lead
4. Positive Load Lead
5. Battery 12. Starttheengineand run the engine at 1500 rpm
6. To Starter (r/min).
7. To Master Disconnect Switch
13. Look at the ammeter in the tester and at the
ammeter in the instrument panel of the machine.
1. Park the machine on a level surface. The test ammeter and the ammeter must indicate
approximately the same amperage. Each 1/8 inch
2. Lower the attachments to the floor. (3.2 mm) into the green range on the ammeter is
approximately 20 amperes.
14. If the test ammeter and the ammeter do not
4. Adjust the controls for the tester as follows: indicate approximately the same amperage, check
the wiring and the connections for the ammeter. If
a. Turn the load control to the OFF position. the wiring and the connection are in good condi-
tion, install a new ammeter in the instrument panel.
b. Select the volt range that will measure 0 to
18 volts.
4004-3
Engine Oil Pressure Gauge

1. Park the machine on a level surface. 17. Make sure the water temperature gauge is in
the green zone and read the engine oil pressure
2. Lower the attachments to the floor. gauge, Make a record of the indication.
4. Remove the cover plate above the instrument

panel to get access to the connections at the en-
gine oil pressure gauge.
5. Disconnect the hose from the fittings on the

engine oil pressure gauge.
6. Connect a pressure gauge to the hose. The

pressure gauge must be accurate in the range of 0
to 80 psi (0 to 552 kPa).
7. Start and run the engine at full throttle.
8. Look at the pressure gauge. The pressure

gauge must indicate a pressure above 45 psi (310
kPa). If the pressure gauge does not indicate the 1. Zero 5. Red
correct pressure, check the hose between the en- 2. 15 psi (103 kPa) 6. Green
3. 85 psi (586 kPa) 7. Amber
gine and the pressure gauge. If the problem is not
4. 100 psi (690 kPa)
found, the problem is in the engine.
9. If the pressure gauge indicated a pressure

above 45 psi (310 kPa), continue to run the engine 18. Compare the indication of the pressure gauge
until the water temperature gauge is in the green in step 12 to the indication of the oil pressure gauge
zone. in step 17. The two indications must be approxi-
mately the same.
10. Run the engine at full throttle.
19. If the two indications are not approximately the
11. Read the pressure gauge. The pressure gauge same, replace the engine oil pressure gauge.
must indicate 50 to 70 psi (345 to 483 kPa). If the
pressure gauge does not indicate this pressure, Transmission Oil Pressure Gauge
check the hose and the tube between the engine
and the pressure gauge. If the problem is not 1. Park the machine on a level surface.
found, the problem is in the engine.
2. Lower the attachments to the floor.
12. If the indication of the pressure was 50 to 70 psi
(345 to 483 kPa), make a record of the indication. 3. Stop the engine and apply the parking brake.
13. Stop the engine. 4. Remove the cover plate above the instrument
panel for access to the back of the transmission oil
14. Disconnect the pressure gauge from the hose. pressure gauge.
15. Connect the hose to the fittings on the engine 5. Disconnect the hose from the connector on the
oil pressure gauge. back of the transmission oil pressure gauge.
16. Start and run the engine at full throttle. 6. Connect a pressure gauge to the hose. The
pressure gauge must be accurate in the range of 0
to 350 psi (0 to 2413 kPa).
4004-4
8. Read the pressure gauge. The pressure gauge

must indicate a pressure above 230 psi (1586 kPa).
If the pressure gauge does not indicate the correct
pressure, check the hose between the torque con-
verter and the pressure gauge. If the problem is not
found, the problem is in the torque converter
charging pump or the pressure regulator.
9. If the pressure gauge indicates a pressure

above 230 psi (1586 kPa), continue to run the en-
gine until the gauge for the torque converter oil
temperature is in the green zone.
10. Run the engine at full throttle.
11. Look at the pressure gauge. The pressure

gauge must indicate 250 to 310 psi (1724 to 2137
1. 160 psi (1103 kPa) 6. 350 psi (2413 kPa)
kPa). If the pressure gauge does not indicate the 2. 210 psi (1448 kPa) 7. RED
correct pressure, check the hose between the tor- 3. 250 psi (1724 kPa) 8. AMBER
4. APPRO XI MA TEL Y 9. GREEN
que converter and the pressure gauge. If the prob- 290 psi (1999 kPa) 10. AMBER
!em is not found, check the torque converter charg- 5. 320 psi (2206 kPa)
Ing pump and the pressure regulator.
~6. Compare the indication of the pressure gauge
12. If the indication of the pressure gauge was 250
1n step 11 to the indication of the transmission oil
to 310 psi (1724 to 2137 kPa), make a record of the
pressure gauge in step 15. The two indications
indication.
must be approximately the same.
13. Stop the engine. Disconnect the pressure
17. If the two indications were not approximately
gauge from the hose. Connect the hose to the
the same, replace the transmission oil pressure
transmission oil pressure gauge in the instrument
gauge.
panel.

Water Temperature Gauge
1. Park the machine on a level surface.
15. Make sure that the gauge for torque converter
oil temperature is in the green area and read the
transmission oil pressure gauge in the instrument
panel. See the drawing above and find the indica-
tion of the transmission oi I pressure gauge. Make a
record of the indication.
4. When the engine has cooled, remove the radia-
tor cap slowly.
Continued on next page

4004-5
5. Start and run the engine at 1500 rpm (r/min). 3. Stop the engine and apply the parking brake.
6. Use a thermometer that will measure 250° F 4. The sensor for the gauge for torque converter
(121 o C) or more. oil temperature is connected to the rear right side
of the torque converter. Put a clean drain pan un-
7. Put the thermometer in the radiator. Make sure der the sensor.
that the end of the thermometer is in the coolant.
5. Remove the sensor from the torque converter.
8. Run the engine until the indication of the ther-
mometer does not change. 6. Put water in a pan. Heat the water to the boiling
point.
9. Make a record of the indication of the ther-
mometer. 7. Put the sensor in the water.
10. Look at the water temperature gauge in the 8. Use a thermometer that will measure 250° F
instrument panel. See the drawing and find the (121 o C) or more.
indication of the water temperature gauge. Make a
record of the indication. 9. Put the end of the thermometer in the water.
10. Compare the indication of the thermometer

with the indication of the gauge for torque conver-
ter oil temperature.
771093
1. 120' F (49' C) 5. 240' F (116' C)

2. 170' F (77' C) 6. AMBER
3. APPROXIMATELY 7. GREEN
180' F (82' C) 8. RED
4. 230' F ( 110' C)
1. 180°F (82°C) 5. GREEN
2. 240°F(116°C) 6. AMBER
3. 260° F (127° C) 7. RED
4. 280° F (138° C) 8. 212°F (100°C)
11. Compare the indication of the water tempera-
ture gauge in step 10 to the indication of the ther-
mometer in step 9. The two indications must be
approximately the same.
same, replace the gauge for torque converter oil
temperature.
same, replace the water temperature gauge.
Gauge for Torque Converter

Oil Temperature

4004-6
Hydraulic Oil Temperature Gauge

{For Machines with Backhoe)
4. Remove the cover from the rear of the hydrau-

lic oil reservoir.
5. Hold a thermometer in the hydraulic oil.
6. Start the engine and run the engine at 2000 rpm 771095
(r/min). 1. 120" F (49" C) 4. 240" F (116" C)
2. APPROXIMATELY 5. GREEN
7. Hold a stabi Iizer control lever in the RAISE posi- 165" F (74" C) 6. RED
3. 210" F (99" C)
tion for 15 seconds. Return the stabilizer control
lever to NEUTRAL for 30 seconds. Repeat this proce-
9. Compare the indications of the hydraulic oil
dure until the temperature of the hydraulic oil is
temperature gauge and the thermometer. The two
approximately 165°F (74°C).
indications must be the same.
8. Look at the hydraulic oil temperature gauge.
See the drawing and find the approximate indica-
same, replace the hydraulic oil temperature gauge.
tion of the temperature of the hydraulic oil.
HOURMETER
If the hourmeter operates when the engine is running and the engine has the correct oil pres-
not running, replace the pressure switch in the line sure. If there is voltage at only one of the terminals,
for the engine oil pressure gauge. replace the pressure switch. If there is voltage at
both of the terminals, check the wires that connect
If the hourmeter does not operate when the the pressure switch to the hourmeter and the hour-
engine is running, check the operation of the pres- meter to the chassis. If the wires are not bad, re-
sure switch. There must be voltage at both termi- place the hourmeter.
nals of the pressure switch when the engine is
4004-7
850486
1. Ammeter 6. Transmission Oil Pressure Gauge

2. Water Temperature Gauge 7. Gauge For Torque Converter Oil Temperature
3. Engine Oil Pressure Gauge 8. Hydraulic Oil Temperature Gauge (For
4. Pressure Switch Machines With Backhoe)
5. Hourmeter
Indicators and Gauges, Mechanical

4004-8
150487
1. Panel Lamp 6. 25 Ampere Circuit Breaker

2. Hourmeter 7. Fuel Shutoff Switch
3. Lamp Switch 8. Pressure Switch
4. Ammeter 9. Horn Switch (If Used)
5. Cold Start Switch (If Used)
Indicators and Gauges, Electrical

4005
BATTERY
TABLE OF CONTENTS
Safety Rules ........................... 4005-2 Preparing a Dry Charged Battery
for Use .............................. 4005-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 4005-3
Using Booster Batteries to Start
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 4005-3 the Engine ........................... 4005-7
Specific Gravity Test .................... 4005-4 Battery Check Sheet .................... 4005-8
Capacity (Load) Test ................... 4005-5
Charging a Battery . . . . . . . . . . . . . . . . . . . . . 4005-5
Written In Clear
And
Simple
English

Issued September, 1985
CASE CORPORATION
4005-2
SAFETY RULES
A WARNING: Never try to charge the bat-

tery if the electrolyte tn the battery is fro-
zen. 47-83
POISON/DANGER: Battery acid causes
severe burns. Batteries contain sulfunc
acid. Avoid contact with skin. eyes. or
clothing. Antidote: EXTERNAL-Flush
with water. INTERNAL-Drink large quanti-
ties of water or milk. Follow with milk of
A WARNING: Never use booster batteries

to start the engine if the electrolyte in the
battery on the machine is frozen. A
magnesia. beaten egg. or vegetable ott.
Call physician immediately. Eyes: Flush
with water for 15 minutes and get prompt
47-82-A medical attention.
Batteries produce explosive gases Keep

sparks. flame. and cigarettes away Venit-
A CAUTION: Never cause sparks to occur
or smoke near batteries that are charging or
have been recently charged. 13-8
late when charging or using in enclosed
area. Always shield eyes when working
near batteries.
Keep out of reach of children. 0-47-53

CAUTION: Disconnect the ground
cable first when the battery cables are dis-
connected from the battery.
A Connect the ground cable last when the

battery cables are connected to the bat-
~~ 4~~
CAUTION: If there ts battery actd tn the

ventilation tube. this battery actd can tw
released when the battery tS turned upstde
h.down. If you tum the battery upstde down .
. . make sure that the end of the venttlattOn
tube is away from you and away from any
other people in the area. Battery actd can
cause severe burns. 48-57
4005-3
SPECIFICATIONS
Electrical System ............................. two 12 volt batteries connected in series, negative ground
System Voltage .............................................................................. 24 volts
Case part number (dry charged) ............................................................. A180406
Size ............................................................................ Group size 31 hybrid
90 second diesel rating ..................................... Current draw of 650 amperes for 90 seconds
at oo F (-18°C} to one volt per cell
Reserve capacity ........................................................................ 170 minutes

Current for capacity (load) test ........................................................... 350 amperes
Cold cranking amperes .................................................................. 700 amperes
Full charge specific gravity ...................................................................... 1.265
Plates per cell . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Weight with electrolyte ............................................................ 56 pounds (25.6 kg)
MAINTENANCE
There is a check sheet at the end of this sec- Electrolyte and dirt on top of the battery can
tion. Make a copy of the check sheet for a record of cause the battery to discharge by making a pas-
the battery inspection and tests. sage for the current to flow.
Electrolyte If damage causes an electrolyte leak, replace

the battery.
Check the level of the electrolyte after every
250 hours of operation. Check the level more fre- Make sure there are no restrictions in the ven-
quently during hot weather. tilation tube.
If the level of the electrolyte is low, add distilled Remove the battery and clean the battery, ca-
water or other clean water until the electrolyte is ble terminals, and battery carrier.·
just below the ring at the bottom of the cell open-
ing. Do not add more water than is needed. Too When available, use Case Battery Saver ac-
much water can cause bad performance, a short cording to the instructions on the container. Case
service life, and corrosion around the battery. Battery Saver also helps prevent corrosion.
NOTE: Add water only, not electrolyte. If Case Battery Saver is not available, use bak-
ing soda or ammonia and water as a cleaner. Then
Inspecting and Cleaning the Battery flush the parts with clean water.
Check the battery at regular intervals for dirt,

corrosion, and damage.
4005-4
SPECIFIC GRAVITY TEST

Procedure 4. Write the corrected reading for the specific
gravity on the check sheet.
A hydrometer is used to check the specific
gravity (weight) of the electrolyte. The specific 5. Repeat steps 1 through 4 for the remainder of
gravity is an indication of the level of charge for the cells.
each cell.
Understanding Results of Specific
Hydrometers are made to show the correct Gravity Check
specific gravity when the temperature of the elec-
trolyte is 80° F (26.7° C). 1. To know the condition of the battery, compare
the readings for specific gravity with the following
When you check the specific gravity, you must chart.
know the temperature of the electrolyte. If your
hydrometer does not have a thermometer, get a
thermometer to check the temperature of the elec- Level of Specific gravity Freezing
trolyte. The thermometer must indicate a high tem- charge at 80°F (26.7°C) temperature
perature of at least 120° F (52° C). 100% 1.260 -75°F (-59°C)
75% 1.230 -38°F (-39°C)
1. Remove enough electrolyte from a cell so that 50% 1.200 -17°F (-27°C)
25% 1.170 1°F (-17°C)
the float is free in the tube.
Discharged 1.110 19°F (-7.2°C)
NOTE: If the specific gravity cannot be checked

without first adding water to the cell, the battery
must be charged for 15 minutes at 15 to 25 amperes 2. If the difference between the high reading and
to mix the water with the electrolyte. Then check the low reading is more than .050, charge the bat-
the specific gravity. tery and check the specific gravity again. If after
charging the difference is still .050 or more, install a
2. Read the float and write the reading on the new battery.
check sheet.
3. If the difference between the high reading and
3. Read the thermometer. If the reading is above low reading is less than .050, and the readings for
80° F (26. 7° C) add gravity points to the reading for specific gravity are 1.225 or more, do the Capacity
specific gravity. If the reading is below 80° F (Load) Test.
(26.7°C} subtract gravity points from the reading
for specific gravity. See the following illustration 4. If the difference between the high reading and
and add or subtract gravity points as needed. the low reading is less than .050 and the specific
gravity is less than 1.225 in one or more cells,
2 charge the battery according to the correct charg-
160- -+.032 70- ing guide or until all cells are 1.225 or more.
+.030
150- -+.028 =-•.028
+.026
140- -+.024 60-
130- -+.020
+.022 =-•.021 a. If the specific gravity did not rise above
•.018
120- -•.016 50- 1.225, install a new battery.
+.014 =-+.014
110- -+.012
+.010 40-
100- -+.008
-~•.006
=-+.007 b. If the specific gravity rose above 1.225, do
90-
30-
+.002 the Capacity (Load) Test.
80-
70- --.004
-.002
26.7---=
20-
-
-.006
60- --.008 =--.007
-.010
50- --.012 10-
-.014
40- --.016 =--.014
-018
30- --.020 0-
-.022 =--.021
20- --.024
-.026
10- --.028 -10-
-.030 =--.028
0- --.032
790863 A
1. Temperature in oF
2. Temperature in o C
4005-5
CAPACITY (LOAD) TEST

The result of the capacity (load) test will show 5. Select the voltmeter range that will measure 12
whether or not the battery is in good condition. If volts.
the test result is equal to or more than the minimum
voltage specification, the battery is in good condi- 6. Select the ammeter range that will measure the
tion. current draw for the battery being tested. See Spec-
ifications on page 4005-3 for the correct current
Minimum Voltage Specification draw.
Temperature of .......................... Volts 7. Move the volt lead switch to the INT position.
electrolyte
8. Check and make a record of the temperature of
70° F (21 o C) and above ..................... 9.6 the electrolyte.
60°F (16°C) ................................ 9.5
50°F (10°C) ................................ 9.4 9. If the battery was charged to do this test, select
40°F (4°C) ................................. 9.3 the ammeter range that will measure 15 amperes.
30°F (-1°C) ................................ 9.1 Turn the load control until the ammeter indicates
20° F (-7°C) ................................ 8.9 15 amperes and keep the load for 15 seconds. Then
10°F (-12°C) ............................... 8.7 select the ammeter range for the current draw.
0°F (-18°C) ................................ 8.5
10. Turn the load control until the ammeter indi-
Test Procedure cates the specified current draw for the battery
being tested. Keep the load for 15 seconds and
1. Make sure the level of charge for the battery is read the voltmeter.
at least 75%. If necessary, charge the battery.
12. Compare the test result and the temperature of
3. Connect the positive load cable to the positive the electrolyte with the minimum voltage specifi-
battery post and the negative load cable to the cation.
negative battery post.
a. If the test result is equal to or more than
4. Install the ammeter clamp on the positive load minimum voltage specification, the battery is
cable so that the arrow is away from the battery. good.
b. If the test result is less than the minimum

voltage specification, the battery is bad.
CHARGING A BATTERY
h
WARNING: Never try to charge the bat- The charging rate must be decreased if:
. . tery if the electrolyte in the battery is fro-
zen. 47-83 1. Too much gas causes the electrolyte to flow
from the cells.
Before you charge the battery, check the level 2. The temperature of the electrolyte rises above
of the electrolyte. 125°F (52°C).
It is difficult to give an exact charging rate NOTE: For the best charge, use the slow charg-
because of the following variable conditions; (1) ing rates.
temperature of the electrolyte, (2) level of charge,
and (3) condition of the battery. Use the charging The battery is fully charged when, over a three
guide for the correct charging rate and time. hour period at a low charging rate, no cell is giving
too much gas, and the specific gravity does not
change.
4005-6
BATTERY CHARGING GUIDE

(6-Volt and 12-Volt Batteries)
Regular and Low Maintenance
Recommended Rate* and Time for Fully Discharged Condition
Battery Capacity - See

Reserve Capacity under
Specifications Slow Charge Fast Charge
80 Minutes or Less 14 Hours at 5 Amperes 1-3/4 Hours at 40 Amperes

7 Hours at 10 Amperes 1 Hour at 60 Amperes
Above 80 to 125 Minutes 20 Hours at 5 Amperes 2-1/2 Hours at 40 Amperes

10 Hours at 10 Amperes 1-3/4 Hours at 60 Amperes
Above 125 to 170 Minutes 28 Hours at 5 Amperes 3-1/2 Hours at 40 Amperes

Above 170 to 250 Minutes 42 Hours at 5 Amperes 5 Hours at 40 Amperes

Above 250 Minutes 33 Hours at 10 Amperes 8 Hours at 40 Amperes

5-1/2 Hours at 60 Amperes
*Initial rate for standard taper charger.

811449A
PREPARING A DRY CHARGED BATTERY FOR USE

1. Fill each cell to the top of separators. This will NOTE: If too much gas causes the electrolyte to
permit an increase in the volume of the electrolyte flow from the ventilation tube or the temperature of
when heated by charging the battery. the electrolyte rises above 125° F (52° C), decrease
the charging rate.
2. Install the caps.
5. If necessary, fill each cell with electrolyte until
3. Connect a battery charger to the battery. the electrolyte is just below the split ring at the
bottom of the cell opening.
4. Charge the battery at 30 amperes unti I the spe-
cific gravity is 1.250 or more and the temperature of
the electrolyte is at least 60°F (15.5°C}.
4005-7
USING BOOSTER BATTERIES TO START THE ENGINE
A WARNING: Never use booster batteries

to start the engine if the electrolyte in the
battery on the machine is frozen.
6. After the engine is running, have another per-
son disconnect the negative(-) cable of the booster
batteries and then the positive (+) cable of the
47-82-A booster batteries.
Connect the booster batteries to the batteries Booster Battery Connections

in your machine according to either of the follow- to the Starter
ing procedures. If you connect the booster batter-
ies in any other way, a spark from the connections The booster batteries must have a total output
can cause an explosion. If you are using another of 24 volts. If you are using another machine for
machine for power, make sure the two machines do power, make sure the two machines do not touch.
not touch.
1. Two persons are required for this procedure.
Booster Battery Connections to
the Machine Batteries 2. Put all of the controls on the NEUTRAL position.
The booster batteries must have a total output
of 24 volts. 3. Apply the parking brake.
1. Two persons are required for this procedure. 4. If the machine has a loader, lower the loader to
the ground or install the support strut on the
2. Put all of the controls in the NEUTRAL position. loader.
3. Apply the parking brake. 5. Have the other person do the following.
4. Have the other person do the following. a. Connect the positive (+)cable of the boos-
ter batteries to the battery terminal of the star-
a. Connect the positive(+) cable of the booster solenoid.
ter batteries to the clamp on the positive (+)
battery cable of the machine. b. Connect the negative (-)cable of the boos-
ter batteries to a good ground connection on
the engine.
b. Connect the negative (-) cable of the boos-
ter batteries to a good ground connection on
machine.
1. Positive ( +) cable 855262
2. Negative (-) cable
1. Positive ( +) cable A846406
2. Negative (-) cable 6. Turn the key switch to the START position and
start the engine.
5. Turn the key switch to the START position and 7. After the engine is running, have the other per-
start the engine. son disconnect the negative (-)cable of the booster
batteries and then the positive (+) cable of the
booster batteries.
4005-8
BATTERY CHECK SHEET

TEST RESULT UNDERSTANDING TEST RESULTS CORRECTION
VIsual
Inspection
1. Dirty battery top Clean.
2. Ventilation tub._e Clean.

closed
3. Corrosion Check for damage to battery case.

Clean.
4. Low electrolyte Add water.

level
5. Crack in case Install new battery.
6. Other defects Install new battery.
Specific Gravity
Check
Cell No.1 1. If the difference between cells 1. Charge the battery. Do the
is more than .050, the battery is specific gravity check again. If the
Cell No. 2 _ _ __ discharged or damaged. difference between cells is still
more than .050, install a new battery.
Cell No. 3 _ _ __
2. If one or more cells are below 2. Charge the battery and do the
Cell No.4 _ _ _ __ 1.225, and all cells are even within specific gravity check again. If the
.050, the battery is discharged. specific gravity rises to 1.225 or
Cell No.5 _ _ _ __ more, do the capacity (load) test.
If the specific gravity stays below
Cell No.6 _ _ _ __ 1.225, intall a new battery.
3. If all cells are at or near full
charge (1.260) and even with .050,
the specific gravity is good. 3. Do the capacity (load) test.
N"OTE; Test results are to be used only with J I

Case original equipment and replacement bat-
teries.--ether types of batteries can give different
tesfrfis-ults.
Capacity (Load)
Test
Load must be'half If the voltage indication is equal to Charge the battery.
of the cold cranking or above the minimum voltage spec-
capacity at oo F ification, the battery is good.
(-17°C)
If the voltage indication is less than Discard the battery.
the minimum voltage specification,
the battery has internal damage.
811448
4006
STARTER AND STARTER SOLENOID
TABLE OF CONTENTS
Specifications .......................... 4006-2 Brushes and Brush Springs .......... 4006-12
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4006-2 Brush Holder ....................... 4006-12
No-Load Test .......................... 4006-2 Armature ........................... 4006-12
Solenoid Test .......................... 4006-6 Field Coil Test ...................... 4006-13
Disassembly ... : . . , .............. _. ..... 4006-7 Assembly ............................. 4006-14
Illustration of Starter : . ............... 4006-7
Inspection ............................ 4006-12
Written In Clear
And
Simple
English

Reprinted November 1985 (680K)
4006-2
SPECIFICATIONS
Case part number and manufacturer 0129494 (Nippondenso)
No-Load Test at 80° F {26.7° C)

Volts ........................................................................................... 23
Current draw ............................................................... 120 amperes maximum
Starter drive speed ....................................................... 4100 rpm (r/min) minimum
LUBRICATION
Interval When the starter is disassembled or each
time the engine is removed for repairs
Lubricant
Molykote-GN .............................................. Use on shaft at pinion end of starter drive
Case multipurpose grease ................................................... Use on bearings, gears,
idler gear shaft and spring.
NO-LOAD TEST
General Information Test Equipment
1. The No-Load Test is done with the starter re- The No-Load Test can be done using a Sun
moved from the engine. Electric VAT-33 Tester, an equivalent tester, or
separate pieces of test equipment.
2. Check to see if you can pull the gear on the
starter drive out of the starter drive housing. A hand held tachometer is needed to measure
the speed of the armature shaft.
3. Check to see if the starter drive can be turned.
Pull the gear on the starter drive out of the starter A remote starter button is needed to actuate
drive housing. Turn the gear to turn the starter the starter.
drive and the armature.
Two fully charged 12 volt batteries connected
4. If the starter drive cannot be turned, disassem- in series are needed to supply the electricity to turn
ble the starter and make repairs as needed.Then do the starter.
the No-Load Test.
4006-3
Test Procedure 3. Connect the positive battery cable to the bat-

tery terminal on the starter solenoid and the nega-
The illustrations in this procedure show the tive battery cable to the mounting flange of the
use of the Sun Electric VAT-33 tester. Other test starter.
equipment can be used. Connect the test equip-
ment according to this procedure and the manu-
facturer's instructions. 0 0
0 o+
1. If the VAT -33 tester is being used: 0 0
a. Select the 0 to 100 ampere range.
0 0
+0 0
b. Select the 18 to 40 volt range. 0 0
2 4
c. Move the volt lead switch to the EXT. posi-
tion.
d. Turn the load control to the OFF position.
850555
1. Jumper Cable
3. Battery Terminal
4. Connect the positive load cable to the positive

post of the battery. Connect the negative load ca-
ble to the negative post.
795328
r------,
2. Fasten the starter in a vise or use another
method to prevent the starter from moving. This
+
must be done to prevent personal injury.
I
I~
II
~
~
-'"-_,.-~~'''''''''''''''''''''''''''''~
850555
1. Positive Load Cable

2. Negative Load Cable
4006-4
5. Connect the positive voltmeter lead to the mo- 7. Fasten the ammeter clamp around the positive
tor terminal on the starter solenoid. battery cable so that the tip of the arrow is toward
the starter.
r------, r------,
+ 0 0
0 0 +
0 0
0 0 0
+ 0 0
;:...,,,,,,,,,,,,~
0 + 0
a-~~~~~·
.;:...,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,
~_.~--·~--~~ ;:...,,,,,,,,,,,,~
0 0
;:...,,,,i
1. Positive Voltmeter Lead

2. Motor Terminal
1. Ammeter Clamp
mounting flange on the starter.
8. Connect the leads from the remote starter but-
r------, ton to the Battery and Switch terminals.
0
0
0
o+ r------,
0 0 0 0
• 0 0 0 0 +
OJ 0 0
+0
0 0_ 0 0
+ 0 0
;:...,,,,,,,,,,,,,~
0 0
850558
1. Negative Voltmeter Lead
1. Remote Starter Button

2. Battery Terminal
3. Switch Terminal
4006-5
IMPORTANT: Steps 9, 10, and 11 must be done 2. Low armature shaft speed and high current
rapidly. Do not load the battery for more than 15 draw are indications of too much friction. Possible
seconds at one time. After the battery has been causes of too much friction are:
loaded for 15 seconds, let the starter cool for 60
seconds. a. Tight, dirty, or worn bearings.
9. Actuate the remote starter button and turn the b. A bent armature shaft.
load control until the voltmeter indicates 22 volts.
c. Loose pole shoes (pole shoes make con-
tact with the armature).
0
0 d. A short circuit in the armature coil. Disas-
0 semble the starter. Use an armature tester to
test the armature. Use the instructions in-
0
cluded with the armature tester.
+0
0 e. Damaged field coil. Do the test on page
4006-13.
3. If the armature does not rotate and the current

draw is high, possible causes are:
a. Field terminal making contact with the

field frame. Inspect the insulators for the field
terminal.
b. Damaged field coil. Do the test on page

4006-13.
c. Damaged bearings.
4. If the armature does not rotate and the current

draw is zero, possible causes are:
a. An open field circuit. Disassemble the star-

ter and inspect the field coil connections.
1. Remote Starter Button b. An open armature coil. Disassemble the

2. Load Control starter and check for burned commutator bars.
3. Voltmeter Use an armature tester to test the armature.
4. Ammeter Use the instructions included with the arma-
5. Hand Held Tachometer ture tester.
10. Look at the ammeter and make a record of the
c. Brushes not making good contact with the
ammeter indication.
commutator bars. Check for high insulation
between the commutator bars, broken brush
11 . Use the hand held tachometer and check the
springs, or worn brushes.
armature shaft speed. Make a record of armature
shaft speed.
5. Low armature shaft speed and low current
draw are indications of:
12. Release the remote starter button and turn the
load control to the OFF position.
a. Dirt or corrosion on connections.
Understanding No-Load b. Damaged wiring.
Test Results
c. Dirty commutator bars.
1. If the current draw and the armature shaft
speed are within the ranges under Specifications, d. All causes in step 4.
the starter is good.
4006-6
6. High armature shaft speed and high current Install a newfield coil. Do the No Load Test again to
draw are indications of a short circuit in the field check for improvement in the operation of the
coil. It is difficult to find a short circuit in a field coil. starter.
SOLENOID TEST
This test will check the condition of the pull-in 4. Connect a jumper cable to the starter mount-
winding and the hold-in winding in the starter sole- ing flange. Connect the other end of the jumper
noid. Use two fully charged batteries to check the cable to the negative post of battery No. 2.
operation of the starter solenoid.
5. Connect a jumper cable to the motor terminal
of the starter solenoid. Connect the other end of
the jumper cable to the negative post of battery No.
2.
6. Connect a jumper cable to the positive post of

battery No. 2.
NOTE: Steps 7 and 9 must be done in a maximum

of 5 seconds to prevent damage to the pu/1-in wind-
ing and the hold-in winding.
7. Connect the opposite end of the jumper cable

that is connected to the positive post of battery No.
2 to the negative post of battery No.1. The pinion
gear on the starter drive must come all the way out
rapidly and with force.
850582
1. Battery No. 1 8. If the pinion gear did not come out rapidly and
2. Battery No. 2 with force, the pull-in winding is damaged. The
3. Battery Terminal complete starter solenoid housing assembly must
4. Switch Terminal be replaced.
5. Motor Terminal
9. Disconnect the jumper cable from the motor
1. Remove the rubber boot from the motor termi- terminal of the starter solenoid. The pinion gear on
nal. Remove the nut and washer from the motor the starter drive must not move toward the starter
terminal. Remove the wire from the motor terminal. drive housing.
2. Connect a jumper cable to the positive post of 10. If the pinion gear started to move toward the
battery No.1. Connect the other end of the jumper starter drive housing, the hold-in winding is dam-
cable to the battery terminal of the starter solenoid. aged. The complete starter solenoid housing as-
sembly must be replaced.
3. Connect a jumper wire to the battery terminal
and the switch terminal on the starter solenoid. The
jumper wire must be made from No. 10 or larger
wire.
4006-7
DISASSEMBLY
r-,
II " ...._
I """',
I """'
\(j '-,
5
850563
1. Cap Screw 11. Field Coil 21. Solenoid Housing

2. Lock Washer 12. Brush Holder 22. Thrust Washer
3. Breather Tube 13. Spring 23. Idler Gear
4. Field Frame Cover 14. Brush 24. Roller (5)
5. Bearing 15. Cover 25. Bearing Cage
6. Armature 16. Gasket 26. Spring
7. 0-ring 17. Plunger 27. Ball
8. Field Frame 18. Nut 28. Drive Clutch
9. Screw 19. Flat Washer 29. Starter Drive Housing
10. Pole Shoe 20. Boot 30. Pinion Gear
4006-8
1. Pull the boot away from the motor terminal and 4. Remove the cover from the armature. Use a soft
remove the nut and flat washer. hammer if necessary.
2. Remove the cap screws and lock washers. 5. Remove the field frame and brush holder.
506420
3. Remove the cover and armature. 6. Make an alignment mark on the field frame and
the brush holder.
4006-9
7. Remove the screws and lock washers that fas- 10. Remove the screws and lock washers from the
ten the field coils to the brush holder. starter drive housing.
506440
8. Remove the brush holder. 11. Remove the starter drive housing from the so-
lenoid housing.
506432
9. Remove and discard the 0-rings from both

ends of the field frame. 12. Remove the pinion gear.
506434 506444
4006-10
13. Remove the drive clutch. 16. Remove the idler gear.
14. Remove the steel ball from the drive clutch. If 17. Remove the bearing cage.
necessary, use a magnet.
18. Remove the thrust washer.

15. Remove the spring.
4006-11
19. Remove the screws and lock washers from the 21. Remove the plunger.
solenoid cover.
506530
20. Remove the solenoid cover. If necessary use a

soft hammer to loosen the solenoid cover.
506538
4006-12
INSPECTION
All parts except the starter drive must be 3. If necessary, put the armature in a lathe and
cleaned using mineral spirits and a brush or cloth. remove enough material from the commutator to
Use a clean, dry cloth to clean the starter drive. make the runout less than .002 inch (0.05 mm).
Brushes and Brush Springs

1. If the length of a brush fastened to the brush
holder is less than 9/16 inch (14 mm), a new brush
holder assembly must be used when the starter is
assembled.
2. If the length of a brush fastened to the field coil

is less than 9/16 inch (14 mm), a new field frame
assembly must be used when the starter is assem-
bled.
3. Using a spring scale to check the tension of the

brush springs. Pull the brush spring up until the 506544
brush spring is just above the brush holder. The

scale indication must not be less than 4 pounds (1.8
kg). If a brush spring is not as specified, use a new 4. Measure the diameter of the commutator. If the
brush spring when the starter is assembled. diameter is less than 1.65 inch (42 mm), install a
new armature.
Brush Holder
1. Hold the leads of an ammeter against two
brushes that are next to each other. Repeat the test
for the other two brushes.
506502
5. If the depth of the groove between the commu-

tator bars is less than .008 inch (0.2 mm), cut the
insulation between the commutator bars to a depth
of .03 to .04 inch (0.7 to 0.9 mm). Use sandpaper to
remove the rough edges from the commutator
2. If there was an indication of a complete circuit, bars.
install a new brush holder.
6. Check the bearings on the armature for free
Armature rotation, rough balls, and damage to the inner race
or outer race. If a bearing is to be replaced, use a
1. Test the armature on an armature tester. Use press and acceptable tools to remove and install
the equipment manufacturer's instructions. the bearings.
2. Put the armature on vee-blocks as-shown and

check the runout of the armature with a dial indica-
tor. The runout must not be more than .002 inch
(0.05 mm).
4006-13
Field Coil Test 3. Hold one of the leads of the ohmmeter against
the end of the cable. Hold the other lead of the
1. Hold the leads of an ohmmeter against one of ohmmeter against one of the leads from the field
the leads from the field coil and against the field coil and read the ohmmeter. Move the lead of the
frame. The needle of the ohmmeter must not move. ohmmeter to the other lead from the field coil and
read the ohmmeter. The needle must move in both
tests.
506508
2. If the needle of the ohmmeter moved, install a

new field assembly.
4006-14
ASSEMBLY
1. Install the plunger. 4. Install the thrust washer.
2. Hold the solenoid cover in position and install 5. Install the bearing cage as shown.
the screws and lock washers that fasten the sole-
noid cover to the solenoid housing.
6. Install the idler gear.
3. Lubricate the bearing cage and the idler gear

with the lubricant specified on 4006-2.
330715
4006-15
7. Install the spring. 11. Install the pinion gear in the starter drive hous-
ing.
8. Lubricate the open bearing on the starter drive

with the lubricant specified on page 4006-2. 12. Assemble the starter drive housing and the
solenoid housing.
9. Install the starter drive into the starter drive
housing.
13. Install the screw and lock washers that fasten

the starter drive housing to the solenoid housing.
10. Put a small amount of grease into the hole in
the starter drive and install the steel ball in the hole.
4006-16
14. Install the brush holder on the field frame. 17. Install the field frame and brush holder onto
Make sure the marks are in alignment. the armature.
15. Install the screws and lock washers that fasten 18. Push each of the brushes in until the springs
the field coils to the brush holder. hold the brushes against the armature.
16. Push each of the brushes toward the outside of 19. Install a new 0-ring on the field frame.
the brush holder until the spring holds the brush
against the brush holder.
4006-17
20. Install the field frame on the solenoid housing. 23. If necessary, use a soft hammer to seat the
cover on the field frame.
506818
21. Install a new 0-ring on the field frame.

24. Install the cap screws and lock washers for the
cover.
506820
22. Install the cover on the armature and the field

frame. Make sure the breather tube in the cover is
toward the solenoid. 25. Install the cable, lock washer, and nut on the
motor terminal and tighten the nut.
506822
26. Pull the boot over the motor terminal.

Section
4007
DELCO-REMY ALTERNATOR

CASE CORPORATION
4007-2
TABLE OF CONTENTS
SPECIFICATIONS ...........................................................................................................................................................2
ILLUSTRATION OF ALTERNATOR ................................................................................................................................3
DISASSEMBLY ...............................................................................................................................................................4
RECTIFIER BRIDGE TEST .............................................................................................................................................9
DIODE TRIO TEST .......................................................................................................................................................10
STATOR TEST ..............................................................................................................................................................10
ROTOR .........................................................................................................................................................................11
Inspection .................................................................................................................................................................11
Resistance Test ........................................................................................................................................................11
Test for Short Circuit ................................................................................................................................................11
ASSEMBLY ...................................................................................................................................................................12
SPECIFICATIONS
Manufacturer ................................................................................................................................................ Delco-Remy
Delco-Remy part number. ..................................................................................................................................11 05537
Case part number ..............................................................................................................................................L112091
Rated output. ................................................................................................................................................ 40 amperes
Rotor resistance .............................................................................................................4.8 to 6 ohms at 80°F (26. 7°C}
Pulley nut torque ..................................................................................................... 40 to 50 pound-feet (54 to 68 Nm)
Bur 8-16550 Issued 9-90 Printed in U.S.A.

4007-3
24. BATTERY
~TERMINAL
~@ 21. INSULATOR
25. BEARING
16. DIODE BRIDGE
11. STATOR
@ 1. NUT
18. BRUSH ~_ 15. SCREW 13. DIODE

10. ROTOR HOLDER 17. FLAT~ , • ~ WITH TRIO
HEAD ~~ "lW WASHE~
SCREW • ' @ 1. NUT
111tb...-. 9. CAP
14.CONDENSER ~ SCREW ~
9. CAP 9. CAP
4. FAN SCREW SCREW 12. INSULATOR
SCREW
(/) ~ ,
5.SPACER ~
8. RETAINER v (j
7. BEARING
(SEALED)
5.SPACER
B840530J
Alternator

4007-4
DISASSEMBLY
STEP 1 STEP4
Make an alignment mark on the front and rear hous- Remove the rear housing.
ings.
STEP 5
STEP 2
Loosen and remove the nuts that hold the leads of the
Loosen and remove the cap screws that hold the alter- stator.
nator together.
STEP 6
STEP 3
Remove the stator.

If necessary, use a screwdriver to separate the stator
and rear housing from the front housing.

4007-5
STEP 7 STEP 10
Touch the red lead of an ohmeter to the brush clip and Loosen and remove the other insulator screw.
the black lead to rear housing as shown. Then make
opposite connections with leads. If both readings were
the same, the insulator on the insulator screw or the STEP 11
voltage regulator is bad. If the insulator is good, the
voltage regulator is bad.
STEP 8
Loosen and remove the flat head screw that holds the
brush holder.
STEP 12
Loosen and remove the insulator screw that holds the
long leg of the diode trio.
STEP 9
Remove the brush holder.
Remove the diode trio.

4007-6
STEP 13 STEP 16
Measure the short side of each brush. If the measure- Loosen and remove the cap screw that holds the lead
ment for either brush is less than 3/8 inch (10 mm), for the condenser.
replace both brushes.
STEP 17
STEP 14
Loosen and remove the cap screw that holds the recti-
Loosen and remove the cap screw that holds the fier bridge.
voltage regulator.
STEP 18
STEP 15
Loosen and remove the nut that holds the rectifier

Remove the voltage regulator. bridge.

4007-7
STEP 19 STEP 22
Remove the rectifier bridge. Do not remove the bearing from the rear housing unless
a new bearing is needed. Reasons for needing a new
bearing are worn or damaged rollers or loss of grease.
STEP 20 DO NOT try to lubricate the bearing. To remove the
bearing, put the rear housing on a hollow support as
shown and press the bearing out of the rear housing.
STEP 23
Remove the BAT terminal and insulator.
STEP 21
Fasten the rotor in a vise that has soft jaws and loosen
and remove the nut.
STEP 24
If necessary, loosen and remove the cap screw that

holds the condenser and remove the condenser.
Use a hammer and brass rod and hit the pulley to

loosen the tapered bushing in the pulley.

4007-8
STEP 25 STEP 28
Remove the pulley, lock washer and tapered bushing. Loosen and remove the cap screws that hold the re-
tainer.
STEP 26
STEP 29
Remove the fan.

Remove the retainer.
STEP 27
STEP 30
If necessary, use a press to remove the rotor from the

front housing. Do not let the rotor fall. Drive the bearing out of the front housing.

4007-9
RECTIFIER BRIDGE TEST

The rectifier bridge has three negative rectifier 3. Repeat step 2 for the remainder of the negative re-
diodes connected to the negative heat sink and termi- ctifier diodes.
nals and three positive rectifier diodes connected to the
positive heat sink and terminals. If a negative rectifier 4. Hold the read lead of the ohmmeter on the positive
diode or a positive rectifier diode has a defect, a new re- heat sink and the black lead on the connector for a
ctifier bridge must be installed. positive rectifier diode. Then hold the red lead on the
connector and the black lead on the positive heat sink.
1. Use a small screwdriver or other tool to separate There must be a high and low reading.
the connectors at the terminals.
5. Repeat step 4 for the remainder of the positive re-

2. Hold the red lead of an ohmmeter on the connector ctifier diodes.
for a negative rectifier diode and the black lead on the
negative heat sink. Then hold the red lead on the 6. If the readings for one negative rectifier diode or
negative heat sink and the black lead on the connector. one positive rectifier diode were the same, a new recti-
There must be a high and low reading. fier bridge must be installed.

4007-10
DIODE TRIO TEST

1. Hold the red lead of an ohmmeter on the long con- 2. Repeat step 1 for the other short connectors.
nector of the diode trio and the black lead on one of the
short connectors. Then hold the red lead on the short 3. If both readings for a short connector were the
connector and the black lead on the long connector. same, a new diode trio must be installed.
There must be a high reading and a low reading.
STATOR TEST
1. Hold one of the leads of an ohmmeter on the 3. Hold one of the leads of the ohmmeter on the
common connection of the stator coils and the other common connection of the stator coils and on one of
lead on the frame. the stator leads. The ohmmeter must show continuity.
2. If the pointer moved, there is a short circuit between

one or more stator coils and the frame. A new stator
must be installed.

4007-11
ROTOR
Inspection 2. Hold one lead of the ohmmeter on one slip ring and
the other lead on the other slip ring.
1. Inspect the rotor shaft at the slip ring end for pitting,
flat areas, and other damage.
2. Check for loose rotor coils. If you find a loose rotor

coil, install a new rotor.
3. Check for broken slip ring connections.
4. Clean dirty slip rings with 400 grit emery cloth. Turn
the rotor to prevent flat areas on the slip rings.
5. Put the rotor in V-blocks as shown and use a dial in-

dicator to check the runout of each slip ring. The runout
must not be more than .002 inch (0.05 mm).
3. The reading must be between 4.8 and 6.0 ohms at
80°F (26. JCC). A small increase in resistance will occur
at higher temperatures and a small decrease in resis-
tance will occur at lower temperatures.
4. If the resistance is not as specified, install a new

rotor.
Test for Short Circuit

1. Hold one lead of the ohmmeter on a slip ring and
the other lead on the shaft.
6. If the runout is more than .002 inch (0.05 mm), put

the rotor in a lathe and remove enough material until the
runout is less than .002 inch (0.05 mm).
Resistance Test
1. Turn the selector of an ohmmeter to Rx1 position.
2. lfthe pointer moved, there is a short circuit between

the rotor coil and the shaft. Install a new rotor.

4007-12
ASSEMBLY
STEP 31 STEP 34
If the bearing was removed from the rear housing, put Install the rectifier bridge.
the rear housing on a hollow support as shown and
press the bearing all the way into the rear housing.
STEP 35
STEP 32
Install and tighten the nut that holds the rectifier bridge.
If necessary, install the condenser and cap screw that

holds the condenser and tighten the cap screw. STEP 36
STEP 33
Install and tighten the cap screw with washer that holds
the rectifier bridge.
Install the BAT terminal and insulator.

4007-13
STEP 37 STEP 40
Install and tighten the cap screw that holds the lead for Install the voltage regulator.
the condenser.
STEP 41
STEP 38
Install and tighten the screw that holds the voltage regu-
If a new voltage regulator is being installed, install the lator.
insulator, lead and nut of the new voltage regulator.
STEP 42
STEP 39 If a new brush holder is being installed:
Tighten the nut.

a. Push the tab on the terminal against the brush
holder.

4007-14
STEP 44
b. Remove the terminal and install the terminal in the

new brush holder.
Install and tighten the flat head screw that holds the
brush holder.
STEP 45
c. Bend the tab over the brush holder to hold the

terminal in place.
Check the condition of the insulator on each insulator

STEP 43 screw. If the insulator is damaged in any way, use a new
insulator screw.
STEP 46
Install the brush holder.
Install and tighten an insulator screw as shown.

4007-15
STEP 47 STEP 50
Install the diode trio. Install and tighten the nuts that hold the stator leads.
STEP 48 STEP 51
Install and tighten the insulator screw that holds the Push the brushes toward the outside until two holes can
lead from the voltage regulator and the long leg of the be seen in the body of the brush holder. Install a tooth-
diode trio. pick or piece of wire through these holes and the hole in
the rear housing as shown to hold the brushes out of the
way.
STEP 49
STEP 52
Install the stator in the rear housing.
If necessary, press a new bearing into the front

housing.

4007-16
STEP 53 STEP 56
Install the retainer. Put the narrow spacer on a hollow support in the press
and put the front housing on the spacer.
STEP 54
STEP 57
Install and tighten the round head screws with lock

washers to hold the retainer. Do not use the original cap Press the shaft of the rotor all the way into the bearing.
screws.
STEP 58
STEP 55
Make sure that the narrow spacer is still in place.

Install the wide spacer on the rotor shaft.

4007-17
STEP 59 STEP 62
Install the fan. Assemble the front and rear housings so that the align-
ment marks are al'igned.
STEP 60
STEP 63
Install the pulley, tapered bushing, and lock washer.

Install and tighten the cap screws that hold the alter-
nator together.
STEP 61
STEP 64
Fasten the rotor in the vise with soft jaws and tighten the
nut to 40 to 50 pound-feet (54 to 68 Nm).
Remove the toothpick.

Section
4008
45 AMP ALTERNATOR- A186124
Printed in U.S.A.
CASE CORPORATION Bur 8-16560
4008-2
TABLE OF CONTENTS
SPECIFICATIONS ...........................................................................................................................................................2
DISASSEMBLY ...............................................................................................................................................................3
ILLUSTRATION OF ALTERNATOR ................................................................................................................................6
INSPECTION ............................................................................................................·...................................................... 7
ASSEMBLY ...................................................................................................................................................................10
SPECIFICATIONS
Rated output ............................................................................................................................... 28 volts at 45 amperes
Resistance of rotor winding ............................................................................................................................. 9.0 ohms
Resistance of stator winding .................................................... :..................................................................... 0.22 ohms
Minimum brush length .... .. .. .. .. .. .. .... ... .. .... ... .... .... .... .... .. .. .. .. .. .. .... .... .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. ... 0.27 inch (7 mm)
Torque for pulley nut.. ................................................................................................................ 50 pound-feet (68 Nm)

4008-3
DISASSEMBLY
STEP 1 STEP 4
Fasten the pulley in a vise with soft jaws and remove the Remove the fan.
nut and lock washer.
STEP 5
STEP 2
Remove the screws and flat washers that fasten the

Tap the pulley with a hammer to loosen the tapered voltage regulator and brush holder to the housing.
bushing in the pulley. Too much force will damage the
bearing in the rear housing. STEP 6
STEP 3
Remove the voltage regulator and brush holder.
Remove the pulley and the tapered bushing.

4008-4
STEP 7 STEP 10
Remove the nut that fastens the lead for the condenser Make alignment marks on the housing, the stator, and
to the terminal. the cover.
STEP 8 STEP 11
Remove the lead, flat washer, and fiber washer from the Remove the screws that fasten the housing, stator, and
terminal. cover together.
STEP 9 STEP 12
Remove the condenser from the housing. Separate the cover and rotor from the stator and
housing.

4008-5
STEP 13 STEP 16
Remove the screws that fasten the rotor to the cover. Remove the screws that fasten the rectifier bridge to the
housing.
STEP 14
STEP 17
Remove the rotor from the cover.

Remove the housing.
STEP 15
STEP 18
Remove the 0-ring from the housing.

Remove the insulator from the terminal.

4008-6
DISASSEMBLY
B852067J
1. Nut 6. Cap Screw 11. Bearing Retainer 16. Terminal Nut 21. Screw and Lock Washer
2. Lock Washer 7. Screw 12. Rotor 17. Insulator 22. Flat Washer
3. Tapered Bushing B. Cover 13. Stator 18. 0-ring 23. Condenser
4. Pulley 9. Spacer 14. Terminal 19. Housing 24. Fiber Washer
5. Fan 10. Bearing 15. Rectifier Bridge 20. Voltage Regulator
Bur 8-16560 and Brush Assembly Issued 9-90 Printed in U.S.A.
4008-7
INSPECTION
STEP 19 STEP 21
Check the stator resistance. The resistance in each coil Check the positive diodes in the rectfier bridge.
must be 0.22 ohm.
Connect the negative lead of the ohmmeter to the
STEP 20 output (B +) terminal. Connect the positive lead of the
ohmmeter to one of the leads for the positive diodes.
The positive diodes are the three diodes that are
closest to the output (B +) terminal. Read the ohmm-
eter.
Reverse the ohmmeter leads. Read the ohmmeter.
There must be a high reading and a low reading. If the

readings are the same, replace the rectifier bridge.
Repeat the procedure for the other two positive diodes.
STEP 22
Check the stator for a short circuit. Make sure the recti-
fier bridge does not touch the stator. Connect one lead
of the ohmmeter to the housing of the stator. Connect
the other lead to each of the three leads from the stator.
If the pointer of the ohmmeter moved, there is a short
circuit in the stator. See step 23 and install a new stator.
Check the negative diodes in the rectifier.
Connect the negative lead of the ohmmeter to the

surface of the diode plate that is not painted. Connect
the positive lead of the ohmmeter to one of the leads for
the negative diodes. Read the ohmmeter.

4008-8
Reverse the ohmmeter leads. Read the ohmmeter. STEP 25
There must be a high reading and a low reading. If the

readings are the same, replace the rectifier bridge.
Repeat the procedure for the other two negative

diodes.
STEP 23
Use the ohmmeter to check the resistance of the rotor

winding. The resistance must be 9.0 ohms.
STEP 26
If any of the diodes are damaged, or if the stator

winding is bad, use a soldering iron to separate the re-
ctifier bridge from the stator. Use a heat setting of at
least 1000 watts and disconnect the wires quickly to
prevent damage to the diodes. Connect the rectifier
bridge to the stator.
STEP 24
Hold one lead of the ohmmeter on the slip ring and the
other lead on the housing. If the pointer moved, there is
a short circuit between the housing and the rotor coil
and the rotor must be replaced.
Inspect the bearings on the rotor. Rotate the bearings

and check for rough spots. If the bearings are
damaged replace the bearings.

4008-9
STEP 27 STEP 28
Measure the length of each brush. The length must be
more than 0.27 inch (7 mm).
STEP 29
Check for continuity between the condenser mounting

tab and the lead. If there is continuity, the condenser is
bad.
Check for continuity between each brush and the brush

terminal. If there is no continuity, replace the brush.

4008-10
ASSEMBLY
STEP 30 STEP 33
Install the insulator on the terminal. Install the fiber washer and then the flat washer on the
terminal.
STEP 31
STEP 34
Install the housing on the rectifier bridge and stator.

Install the lead for the condenser on the terminal.
STEP 32
STEP 35
Install the screws that fasten the rectifier bridge to the

housing. Install the flat washer and the nut on the terminal.

4008-11
STEP 36 STEP 39
Install the condenser on the housing. Install the rotor in the cover.
STEP 37 STEP 40
Check for a s'hort circuit between the terminai and the Install the screws that fasten the rotor to the cover.
housing. If there is continuity, the insulator is bad.
STEP 41
STEP 38
Make sure the marks are in alignment and install the

Install the 0-ring in the housing. cover and rotor in the stator and housing.

4008-12
STEP 42 STEP 45
Install the screws that fasten the housing, stator, and Install the fan.
cover together. Tighten the screws evenly.
STEP 46
STEP 43
Install the pulley and the tapered bushing.

Install the voltage regulator and the brush holder. Be
careful not to damage the brushes. STEP 47
STEP 44
Install the lock washer and start the nut onto the shaft.
Install the screws and flat washers.

4008-13
STEP 48
Fasten the pulley in a vise with soft jaws. Tighten the nut
to 50 pound-feet (68 Nm).

Section
4009
45 AMP ALTERNATOR A187916
CASE CORPORATION Bur 8-16570 Printed in U.S.A.

4009-2
TABLE OF CONTENTS
SPECIFICATIONS ...........................................................................................................................................................2
DISASSEMBLY ...............................................................................................................................................................3
INSPECTION OF BRUSHES ..........................................................................................................................................8
INSPECTION AND TESTING OF ROTOR ......................................................................................................................9
INSPECTION AND TESTING OF STATOR ..................................................................................................................10
TESTING THE CONDENSER .......................................................................................................................................11
TESTING THE RECTIFIER BRIDGE .............................................................................................................................12
ASSEMBLY ...................................................................................................................................................................14
SPECIFICATIONS
Rated output. .............................................................................................................................. 28 volts at 45 amperes
Resistance of rotor .................................................................................................................................8.1 to 9.9 ohms
Maximum runout for slip rings ......................................................................................................0.002 inch (0.05 mm)
Minimum diameter of slip rings ....................................................................................................1.055 inch (26.8 mm)
Resistance of stator ...........................................................................................................................0.20 to 0.24 ohms
Minimum length of brushes .................................................................................................................0.27 inch (7 mm)
Torque for nut for pulley ......................................................................................... 44 to 55 pound-feet (60 to 70 Nm)

4009-3
DISASSEMBLY
STEP 1 STEP 4
Fasten the pulley in a vise that has soft jaws and loosen Remove the fan.
and remove the nut and lock washer.
STEP 5
STEP 2
Hold the voltage regulator and brush holder and loosen

Hit the pulley with a hammer to loosen the tapered and remove the screws.
bushing.
STEP 6
STEP 3
Remove the voltage regulator and brush holder.

Remove the pulley and tapered bushing.

4009-4
STEP 7 STEP 10
Make an alignment mark on the front and rear hous- Remove the front housing and rotor from the rear
ings. housing.
STEP 8 STEP 11
Loosen and remove the screws that hold the front and Loosen and remove the screws that hold the retainer for
rear housings together. the rotor.
STEP 9 STEP 12
Hold the stator and hit the front housing with a soft Remove the rotor.
hammer to separate the front housing from the stator.

4009-5
STEP 13 STEP 16
Use an acceptable puller and press the rotor out of the Loosen and remove the screw that holds the con-
spacer and bearing. denser.
STEP 14 STEP 17
Remove the retainer. Disconnect the lead from the condenser from the
terminal and remove the condenser.
STEP 15
STEP 18
Use an acceptable puller and drive and press the rotor

out of the other bearing. Loosen and remove the two screws that hold the recti-
fier bridge.

4009-6
STEP 19 STEP 22
Loosen and remove the nut, lock washer and flat Remove the insulators from the D + terminal.
washer from the B + terminal.
STEP 23
STEP 20
Use a screwdriver and separate the stator from the rear

Remove the insulators from the B + terminal. housing.
STEP 21 STEP 24
Loosen and remove the nut, lock washer and flat Carefully remove the stator and rectifier bridge from the
washer from the D + terminal. rear housing.

4009-7
STEP 25 STEP 27
Turn the insulator off of the D + terminal. Use a screwdriver to start the cover for the slip rings out
of the rear housing.
STEP 26
STEP 28
Remove the insulator for the B + terminal.

Use an acceptable tool to remove the coverJrom the
rear housing. ''

4009-8
INSPECTION OF BRUSHES
STEP 29 STEP 32
Use an ohmmeter and check the continuity from each To replace the brushes, use a soldering iron to remove
terminal and brush. If the reading is zero, replace the the original brushes. Install the springs and new
brush or voltage regulator and brush holder. brushes and use rosin core solder to solder the leads to
the terminals. Before soldering the terminal shown,
open the sleeve for the brush lead and then crimp the
STEP 30 sleeve.
STEP 33
Remove the shield.
STEP 31 Install the shield.
Measure the length of each brush. If the length of one

brush is less than 0.27 inch (7 mm) replace both
brushes or the volatage regulator and brush holder.

4009-9
INSPECTION AND TESTING OF ROTOR

STEP 34 STEP 36
Touch the leads of the ohmmeter to the slip rings. The Use a dial indicator and measure the runout of each slip
reading must be 8.1 to 9.9 ohms. If the reading is not as ring. If the runout is more than 0.002 inch (0.05 mm) a
specified, a new rotor must be installed. new rotor must be used or use use a lathe to remove
enough material until the runout is less than specified.
STEP 35
STEP 37
Touch the leads to each slip ring and the shaft. If a

reading shows continuity, a new rotor must be installed. Measure the diameter of the slip ring. The diameter
must not be less than 1.055 inch (26.8 mm).

4009-10
INSPECTION AND TESTING OF STATOR

STEP 38 STEP 41
Look for burned insulation on the coils of the stator. This
is an indication of a short circuit. Install a new stator.
STEP 39
Use a high watt soldering iron and rosin core solder to

solder the leads of the stator to the rectifier bridge.
Touch the leads of the ohmmeter to each lead from the

stator and the common connection. The readings must
be 0.20 to 0.24 ohm. If the readings are not as speci-
fied, a new stator must be installed.
STEP 40
Touch the leads of the ohmmeter to each lead from the

stator and the frame. If a reading shows continuity, a
new stator must be installed.

4009-11
TESTING THE CONDENSER

STEP 42 STEP 43
Touch the terminal to the bracket to discharge the con-
denser.
Touch the leads of the ohmmeter to the condenser as

shown. The reading will increase and then return to zero
resistance as the condenser is charged. If there is no in-
dication of resistance, a new condenser must be in-
stalled. The condenser is used to reduce radio noise.

4009-12
TESTING THE RECTIFIER BRIDGE

STEP 44 STEP 45
Touch the leads of the ohmmeter to a positive diode Touch the leads of the ohmmeter to a negative diode
and the heat sink as shown. Then reverse the leads. and the heat sink as shown. Then reverse the leads.
There must be a high reading and a low or zero reading. There must be a high reading and a low or zero reading.
Then test the other two positive diodes. If a positive Then test the other two negative diodes. If a negative
diode did not have readings as specified, the positive diode did not have readings as specified, the negative
diode is bad and a new rectifier bridge must be instal- diode is bad and a new rectifier bridge must be in-
led. stalled.
NOTE: If the tester you are using has a diode test func-
tion, use the tester according to the instructions of the
manufacturer to check the positive and negative
diodes.

4009-13
1· SCREW
~
8. NUT~
5. REAR HOUSING
12.SPACER
1· SCREW
10. VOLTAGE
AND BRUSH REGULATOR
HOLDER ~~~NG 14. RETAINER
~ 13. BEARING
~ ~BNUT
~ 7. LOCK WASHER
17. TAPERED BUSHING
18. PULLEY
~
20. FRONT HO USING 1· SCREW
-
1. SCREW
.......
B901128J
Bur 8-16570 Issued 9_90 Printed in U.S.A.

4009-14
ASSEMBLY
STEP 46 STEP 49
Align the boss on the cover with the notch in the rear Turn the insulator all the way onto the D + terminal.
cover.
STEP 50
STEP 47
Install the stator and rectifier bridge assembly in the

Use an acceptable driver and a small hammer and ca- rear housing.
refully drive the cover into the rear housing.
STEP 51
STEP 48
Pull the D + terminal and insulator into alignment with

Install the insulator for the B + terminal. the rear housing.

4009-15
STEP 52 STEP 55
Install and tighten the two screws that hold the rectifier Install the insulators on the B + terminal.
bridge.
STEP 56
STEP 53
Install the flat washer, lock washer and nut on the B +

Install the insulators on the D + terminal. terminal. Tighten the nut.
STEP 54 STEP 57
Install the flat washer, lock washer and nut on the D + Install the lead from the condenser on the B + terminal.
terminal. Tighten the nut.

4009-16
STEP 58 STEP 61
Install and tighten the screw that holds the condenser. Install the spacer with the smooth surface up.
STEP 59 STEP 62
Install the retainer with the smooth side up. Use an acceptable driver and press the bearing and
spacer all the way onto the shaft.
STEP 60
STEP 63
Install the bearing.

Use an acceptable driver and press the other bearing
all the way onto the shaft.

4009-17
STEP 64 STEP 67
Install the rotor in the front housing. Install and tighten the screws that hold the alternator to-
gether.
STEP 65
STEP 68
Align the retainer with the front housing and install and
tighten the screws. Install the voltage regulator and brush holder.
STEP 66 STEP 69
Assemble the front and rear housings so that the align- Hold the voltage regulator and brush holder in place
ment marks are aligned. and install and tighten the screws.

4009-18
STEP 70 STEP 72
Install the fan. Install the lock washer and nut.
STEP 71 STEP 73
Install the pulley and tapered bushing. Fasten the pulley in a vise that has soft jaws and tighten
the nut to 44 to 50 pound-feet (60 to 70 Nm).

Section
5501
INSPECTION OF TRACK SYSTEM COMPONENTS

CASE CORPORATION
5501-2
TABLE OF CONTENTS
SPECIAL TOOL ..............................................................................................................................................................3
INTRODUCTION .............................................................................................................................................................3
PIN AND BUSHING WEAR FOR SEALED TRACK ........................................................................................................4
PIN AND BUSHING WEAR FOR CASE LUBRICATED TRACK .....................................................................................5
TRACK LINK WEAR .......................................................................................................................................................6
TRACK SHOE WEAR .....................................................................................................................................................7
TRACK AND CARRIER ROLLER WEAR ........................................................................................................................8
IDLER WEAR ................................................................................................................................................................10
WEAR CHART FOR PIN AND BUSHING WEAR (PITCH EXTENSION)
FOR SEALED TRACK WITH 6.25 IN (158. 7 mm) PITCH ........................................................................................11
FOR SEALED TRACK WITH 6. 73 IN (171 mm) PITCH ...........................................................................................12
WEAR CHART FOR FORWARD AND REVERSE BUSHING WEAR
FOR SEALED TRACK WITH 6.25 IN (158. 7 mm) PITCH ........................................................................................13
FOR SEALED TRACK WITH 6.73 IN (171 mm) PITCH ........................................................................................... 14
WEAR CHART FOR VERTICAL BUSHING WEAR
FOR SEALED TRACK WITH 6.25 IN (158.7 mm) PITCH ........................................................................................15
FOR SEALED TRACK WITH 6. 73 IN (171 mm) PITCH ...........................................................................................16
FOR CASE LUBRICATED TRACK WITH 6.25 IN (158.7 mm) PITCH ..................................................................... 17
FOR CASE LUBRICATED TRACK WITH 6.73 IN (171 mm) PITCH ........................................................................ 18
FOR CASE LUBRICATED TRACK WITH 6.25 IN (158.7 mm) PITCH ........................................................ ;............ 19
FOR CASE LUBRICATED TRACK WITH 6.73 IN (171 mm) PITCH ........................................................................20
WEAR CHART FOR TRACK LINK WEAR WITH 6.25 IN (158.7 mm} PITCH ..............................................................21
WEAR CHART FOR TRACK LINK WEAR WITH 6.73 IN (171 mm) PITCH .................................................................22
WEAR CHART FOR ONE BAR TRACK SHOE WEAR .................................................................................................23
WEAR CHART FOR TWO BAR TRACK SHOE WEAR ................................................................................................24
WEAR CHART FOR THREE BAR TRACK SHOE WEAR .............................................................................................24
WEAR CHART FOR TRACK ROLLER WEAR ..............................................................................................................25
WEAR CHART FOR CARRIER ROLLER WEAR ...........................................................................................................26
WEAR CHART FOR IDLER WEAR ...............................................................................................................................27
TRACK COMPONENT APPRAISAL FORM ..................................................................................................................28

5501-3
SPECIAL TOOL
The special tools shown are used to measure the wear
of track system components. Order special tools from
one of the following addresses:
In the U.S.A. and Canada
Service Tools
P.O. Box 314
Owatonna, MN 55060
In Europe
VL Churchill Ltd
P.O. Box 3, Daventry CAS-1950 Measuring Tools Kit. Not shown in use.
Northants, NN11 4NF
England
INTRODUCTION
The purpose of this section is to help the service tec- 2. Case Lubricated Track (CLT) which is assembled
hnician to measure as accurately as possible the wear with oil. Seals are installed at each end of the bushings
of track system components, and to understand the to keep the lubricant in the bushing.
cause of the wear.
Also, by measuring wear and using the charts in this

section the service technician will be able to determine
the remaining life of many of the components.
Two types of track systems are used on this

machine:
1. Sealed track which is a~sembled with grease. Two

Belleville springs are installed at each end of the
bushings to prevent dirt from entering the bushings.
3. BUSHING B900616J
The remainder of the track system components are the

same for the sealed track and Case Lubricated Track.
To determine if the machine is being used in a low or

high impact working condition, see the following defini-
tions.
A low impact condition is when the bar(s) on the

track shoe completely engage the ground and the
ground is free of bumps.
A high impact condition is when the bar(s) on the

track shoe do not completely engage the ground and
there is constant contact with bumps six inches (150
mm) or higher.

5501-4
PIN AND BUSHING WEAR FOR SEALED TRACK

Because of the constant force applied to the the pins Use the small caliper from the CAS-1950 kit and
and bushings in forward and reverse, wear occurs on measure the wear on the front and rear of a bushing as
the ID of the bushing and the OD of the pin surface shown. Make several measurements across the worn
inside the bushing. This wear is normal. The deflection area to find the most wear. Make sure that the bushing
of the track chain is important because the tighter the is clean and that the caliper is 90 degrees to the
track chain, the faster the wear. bushing. Record the measurements on the Track Com-
ponent Appraisal Form. Measure two more bushings
To measure internal bushing and pin wear, measure at 3 to 4 feet {0.9 to 1.2 M) intervals and record the
the track pitch in three places. When measuring the measurements on the Track Component Appraisal
track pitch, the measurement must be taken at least Form. See the chart on page 13 or 14 to find the percent
four track links away from the master link and master of wear.
pin. The master pin has a hole in each end. Use the
track adjuster to tighten the track chain. Measure from
the front of a track pin to the front of the fifth track pin. If
using a tape measure, do not use the hook to hold the 3. FORWARD OR
tape measure. Make a record of the measurements on REVERSE- 1. FORWARD OR
the Track Component Appraisal Form. WEAR /-....;....+-REVERSE WEAR
2. VERTICAL
WEAR B900594J
Use the depth gauge to measure the vertical wear of

a bushing as shown. Make several measurements
across the worn area to find the most wear. Make sure
See the chart on page 11 or 12. If the measurement that the bushing and track shoe are clean and that the
was equal to 70% worn or less turn the pins and depth gauge is perpendicular to the track shoe. Record
bushings for maximum life of these parts. the measurement on the Track Component Appraisal
Form. Measure two more bushings at 3 to 4 feet (0.9 to
As the bushings move around the sprocket, the 1.2 M) intervals and record the measurements on the
bushings also wear on the OD of the bushings. The Track Component Appraisal Form. See the chart on on
faster the speed of the machine and excessive use of page 15 or 16 to find the percent of wear.
reverse, the faster the wear of the bushings.
Increased track pitch is also a cause of wear on the

OD of the bushings. As the track pitch increases, the
bushings come into contact with the sprocket teeth
nearer the ends of the sprocket teeth and slide to the
bottom of the sprocket teeth. This wear occurs on the
rear of the bushings.
B900595J

5501-5
PIN AND BUSHING WEAR FOR CASE LUBRICATED TRACK

Because the lubricant in the bushing decreases wear One of two methods can be used to measure the
on the ID of the bushings and the OD of the pin to a wear of the bushings. Both are shown.
minimum amount, the track pitch does not increase to
cause faster wear on the OD of the bushings. Use the small caliper and measure the wear on the
front and rear of a bushing as shown. Make several
As the bushings move around the sprocket, wear measurements across the worn area to find the most
occurs on the OD of the bushings. The wear occurs on wear. Make sure that the bushing is clean and that the
the front and rear of the bushings. The faster the speed caliper is 90 degrees to the bushing. Record the
of the machine and excessive use of reverse, the faster measurements on the Track Component Appraisal
the wear of the bushings. Form. Measure two more bushings at 3 to 4 feet (0.9 to
1.2 M) intervals and record the measurements on the
Rapid wear of the bushings is caused by operating Track Component Appraisal Form. See the chart on
the machine when the tracks are too tight. The tight page 17 or 18 to find the percent of wear.
track chain increases the pressure between the
bushings and sprocket teeth which causes more
friction and rapid wear on the bushing OD. Tight tracks
are caused by wrong adjustment and mud or other
1. FORWARD OR
debris filling the sprocket teeth. REVERSE --~\ 1. FORWARD OR
l•-+-i'--- REVERSE WEAR
WEAR
To help prevent wear caused by tight tracks, adjust
the deflection of the track according to instructions in
Section 5504. Remember, if the sprocket teeth are filled
with mud or other debris, adjust the track deflection
without cleaning the sprocket teeth. B900594J
Vertical wear of the bushings is caused by changing Use the depth gauge to measure the vertical wear of
directions. Each time the machine changes direction a bushing as shown. Make several measurements
the bushings slide across the bottom of the teeth before across the worn area to find the most wear. Make sure
touching the forward or reverse drive side of the that the bushing and track shoe are clean and that the
sprocket teeth. Another cause of vertical wear is track depth gauge is perpendicular to the track shoe. Record
chains that are too tight because the track chain is not the measurement on the Track Component Appraisal
adjusted correctly or because of packing. Form. Measure two more bushings at 3 to 4 feet (0.9 to
1 .2 M) intervals and record the measurements on the
Internal wear of the bushing will occur when the lub- Track Component Appraisal Form. See the chart on
ricant has been lost. Dry bushings will feel warm. page 19 or 20 to find the percent of wear.
B900595J

5501-6
TRACK LINK WEAR

The only wear that can be measured is wear of the rail Shown below is wear on the side of the rail. This wear
(top) on the track links. This wear is caused by the occurs because of contact with the flanges on the
rolling and sliding contact with the track and carrier rollers and the idler. This wear will occur faster during
rollers and the idler. Other causes of wear are speed, a side hill operation, turning, and with increased track
tight track chain, track shoe width, the work environ- pitch which makes the track flexible.
ment and increased track pitch.
To measure the height of the track links (wear of rail),

assemble the rulers in the CAS-1950 kit. Make sure that
the rail and the bottom of the track shoe are clean. Make
the measurement in the areas shown in the illustration
at the bottom of this column. Make sure that the vertical
ruler is at 90 degrees to the track shoe. Record the
smallest measurement on the Track Component Ap-
praisal Form. Measure two more track links at 3 to 4 feet
(0.9 to 1.2 M) intervals and record the measurements
on the Track Component Appraisal Form. See the chart Shown below is wear on the top of the boss for the
on page 21 to find the percent of wear. pin. This wear is caused by the flanges on the track
rollers because of the decreased height of the track
links and the decreased diameter of the track rollers.
This is the result of bad maintenance and track system
management.
B900596J
Shown below is uneven wear on the rail. Wear over

the pins will occur faster because of the narrow width of
the rail and contact with the rollers. This wear can also
be caused by working on an uneven surface (rocks)
which can cause the track rail to hit the roller(s). Shown below is wear on the inside of the track link.
This wear is cause by contact with the tips of the
The wear in the center of the rail is caused by contact sprocket teeth. This wear occurs because the sprocket
with the idler and carrier and track rollers. is not aligned with the track and rear track roller, in-
creased track pitch which makes the track flexible, side
hill operation and wide track shoes.

5501-7
Shown below is a cracked track link. The most

probable cause of cracks is using track shoes that are
too wide and are carrying the weight of the machine
near the ends of the track shoes.
B900601J
TRACK SHOE WEAR

The only wear that can be measured is the wear of the Shown below is a cracked grouser and a broken
grouser on the track shoe. This wear is normal. corner on the track shoe. This is caused by using track
shoes that are too wide for use on rough terrain.
To measure the height of the grouser, use the track
adjuster to tighten the track chain. Use the depth
gauge in the CAS-1950 kit to measure the height of the
grouser 1/3 of the way from the end of the track shoe as
shown. Record the measurement on the Track Com-
ponent Appraisal Form. See the chart on page 23 or 24
find the percent of wear.
8900613J
Shown below are worn bolt holes in a track shoe. This

is caused by loose bolts. Make sure that the bolts are
tightened to the specified torque.
B901624J
Shown below are worn or broken corners on the ends

of the grouser. This is caused by working on rough
terrain.

5501-8
TRACK AND CARRIER ROLLER WEAR

The only wear that can be measured is wear on the If the track rollers are to be rotated, see the diagram
treads of the roller. This wear is normal and occurs as below.
the track links move under or over the rollers. The front
and rear track roller wear faster than the track rollers
between them. Measure the middle track rollers first
and more often. The reason for this is that when the
middle rollers are 40% worn, it is recommended that the
track rollers be rotated to increase the life of all the track
rollers.
B900603J
If equipped with track guides (rock guards) loosen
and remove the cap screws that hold the track guides
and remove the track guides. It is important to measure Shown below is normal tread wear.
both treads for an accurate indication of wear. When in-
stalling the track guides, apply Loctite 242 to the
threads on the cap screws.
Use the large caliper from the CAS-1950 kit and

measure both treads as shown. Make sure that the
treads are clean. Measure at the center of the treads
because this is the area of the most wear. Record the
measurements on the Track Component Appraisal
Form. See the chart on pages 25 or 26 to find the
percent of wear.
B900602J

5501-9
Shown below is wear on the side of the flanges. This Shown below are flat areas on the treads of a carrier
wear is caused by side hill operation, extended track roller. This wear is caused by the track links sliding on
pitch which makes the track flexible, the front and rear the tread because the roller does not rotate. The same
track rollers not aligned with the idler and sprocket, and wear can occur on the track rollers. Keep the area
the carrier roller not aligned with the track. around the rollers clean to prevent this wear.
B900607J
Shown below is wear on the 00 of the flanges. This

wear is caused by wear on the rail on the track links and
wear on the tread of the roller which causes the flanges
to touch the bosses for the pins in the track links. This is
the result of bad maintenance and track system man-
agement.

5501-10
IDLER WEAR
The only wear measured on the idler is the tread Shown below is wear on the side of the flange. This
wear. This wear is normal and is caused by the track wear is caused by side hill operation, extended track
links moving around the idler. pitch which makes the track flexible and the carrier roller
not aligned with the track. Check the idler alignment ac-
Use the depth gauge to measure tread wear as cording to instructions in Section 5508.
shown. Make sure that the treads are clean. Measure at
the center of the treads because this is the area of the
most wear. Record the measurements on the Track
Component Appraisal Form. See the chart on page 27
to find the percent of wear.
B900609J
Wear on the OD of the flange is caused by packing

between the track links and packing behind the idler
roller. This wear is of little importance except when
measuring tread wear.
B900608J
B900610J
Bur 8-16580 Issued 9-90 Pfinted in U.S.A.

5501-11

FOR SEALED TRACK WITH 6.25 IN (158.7 mm) PITCH
Inch Percent Worn (mm)

25.03 0 635.76
25.05 5 636.27
25.07 10 636.78
25.09 15 637.29
25.11 20 637.79
25.13 25 637.79
25.15 30 638.30
25.17 35 638.81
25.19 40 639.32
25.21 45 639.83
25.23 50 640.33
25.25 54 640.84
25.27 58 641.35
25.29 62 641.86
25.31 66 642.37
25.33 70 643.38
25.35 73 643.89
25.37 76 644.40
25.39 79 644.91
25.41 82 645.41
25.43 85 645.92
25.45 88 646.43
25.47 91 646.94
25.49 94 647.45
25.51 97 647.95
25.53 100 648.46
Turn pins and bushings at or before this point.
It is recommended pins and bushings be replaced

if wear is beyond this point.
25.55 103 648.97

25.57 106 649.48
25.59 109 649.99
25.61 112 650.49
25.63 115 651.00
25.65 118 651.51
25.67 121 652.02
25.69 124 652.53

5501-12

FOR SEALED TRACK WITH 6. 73 IN (171 mm) PITCH
a=:
.~,.
~ ~~
26.97 0 683.26
26.99 5 685.54
27.01 10 686.05
27.03 15 686.56
27.05 20 687.07
27.07 25 687.58
27.09 30 688.09
27.11 35 688.59
27.13 40 689.10
27.15 45 689.61
27.17 50 690.12
27.19 54 690.64
27.21 58 692.15
27.23 62 691.64
27.25 65 692.15
27.27 70 692.66
27.29 73 693.17
27.31 76 693.67
27.33 79 694.18
27.35 82 694.69
27.37 85 695.20
27.39 88 695.71
27.41 91 696.21
27.43 94 696.72
27.45 97 697.23
27.47 100 697.74
Turn pins and bushings at or before this point.
It is recommended pins and bushings be replaced

if wear is beyond this point.
27.49 103 698.25

27.51 106 698.75
27.53 109 699.26
27.55 112 699.77
27.57 115 700.28
27.59 118 700.79
27.61 121 701.29
27.63 124 701.80

5501-13
WEAR CHART FOR FORWARD AND REVERSE BUSHING

WEAR FOR SEALED TRACK WITH 6.25 IN (158.7 mm) PITCH
89005945
Inch Percent worn for Percent worn for (mm)

high impact conditions low impact conditions
2.12 0 0 53.85
2.11 10 8 53.59
2.10 20 16 53.34
2.09 30 24 53.09
2.08 40 31 52.83
2.07 50 38 52.58
2.06 60 45 52.32
2.05 70 52 52.07
2.04 76 59 51.82
2.03 82 66 51.56
2.02 88 72 51.31
2.01 94 78 51.05
2.00 100* 84 50.80
1.99 103 90 50.55
1.98 106 92 50.29
1.97 109 94 50.04
1.96 112 96 49.78
1.95 114 98 49.53
1.94 116 100* 49.28
1.93 118 102 49.02
1.92 120 104 48.77
*Turn pins and bushings before this point.

It is recommended pins and bushings be
replaced if wear is beyond this point.

5501-14

WEAR FOR SEALED TRACK WITH 6.73 IN (171 mm) PITCH
89005945

2.24 0 0 56.90
2.23 9 7 56.64
2.22 19 16 56.39
2.21 29 24 56.13
2.20 38 32 55.88
2.19 48 40 55.63
2.18 57 48 55.37
2.17 66 56 55.12
2.16 76 64 54.86
2.15 81 72 54.61
2.14 86 77 54.36
2.13 91 82 54.10
2.12 95 87 53.85
2.11 100* 90 53.59
2.10 102 92 53.34
2.09 104 94 53.09
2.08 106 95 52.83
2.07 108 97 52.58
2.06 110 99 52.32
2.05 112 100* 52.07
2.04 114 102 51.82
2.03 116 103 51.56
2.02 118 105 51.31
2.01 120 106 51.05
2.00 122 108 50.80


5501-15

FOR SEALED TRACK WITH 6.25 IN (158.7 mm) PITCH
B900595S

2.67 0 0 67.82
2.66 10 8 67.56
2.65 20 16 67.31
2.64 30 24 67.06
2.63 40 31 66.80
2.62 50 38 66.55
2.61 60 45 66.29
2.60 70 52 66.04
2.59 76 59 65.79
2.58 82 66 65.53
2.57 88 72 65.28
2.56 94 78 65.02
2.55 100* 84 64.77
2.54 103 90 64.52
2.53 106 92 64.26
2.52 109 94 64.01
2.51 112 96 63.75
2.50 114 98 63.50
2.49 116 100* 63.25
2.48 118 102 62.99
2.47 120 104 62.74


5501-16

FOR SEALED TRACK WITH 6.73 (171 mm) PITCH
B900525S

2.81 0 0 71.37
2.80 9 7 71.12
2.79 19 16 70.87
2.78 29 24 70.61
2.77 38 32 70.34
2.76 48 40 70.10
2.75 57 48 69.85
2.74 66 56 69.60
2.73 76 64 69.34
2.72 81 72 69.09
2.71 86 77 68.83
2.70 91 82 68.58
2.69 95 87 68.33
2.68 100* 90 68.07
2.67 102 92 67.82
2.66 104 94 67.56
2.65 106 95 67.31
2.64 108 97 67.06
2.63 110 99 66.80
2.62 112 100* 66.55
2.61 114 102 66.29
2.60 116 103 66.04
2.59 118 105 65.79
2.58 120 106 65.53
2.57 122 108 65.28


5501-17

WEAR FOR CASE LUBRICATED TRACK WITH 6.25 IN (158.7 mm) PITCH
89005948

2.12 0 0 53.85
2.11 7 5 53.59
2.10 14 10 53.34
2.09 21 15 53.09
2.08 28 20 52.83
2.07 35 25 52.58
2.06 42 30 52.32
2.05 48 35 52.07
2.04 54 40 51.82
2.03 59 45 51.56
2.02 64 50 51.31
2.01 68 54 51.05
2.00 72 58 50.80
1.99 76 62 50.55
1.98 80 65 50.29
1.97 84 68 50.04
1.96 88 71 49.78
1.95 91 74 49.53
1.94 94 76 49.28
1.93 97 78 49.02
1.92 100* 80 48.77
1.91 103 82 48.51
1.90 106 84 48.26
1.89 109 86 48.01
1.88 112 88 47.75
1.87 115 90 47.50
1.86 118 92 47.24
1.85 121 94 46.99
1.84 96 46.74
1.83 98 46.48
1.82 100* 46.23
1.81 102 45.97


5501-18

FOR CASE LUBRICATED TRACK WITH 6.73 IN (171 mm) PITCH
B900594S

2.24 0 0 56.90
2.23 5 4 56.64
2.22 10 8 56.39
2.21 15 12 56.13
2.20 20 15 55.88
2.19 25 19 55.63
2.18 30 23 55.37
2.17 35 27 55.12
2.16 40 31 54.86
2.15 45 35 54.61
2.14 50 39 54.36
2.13 55 42 54.10
2.12 60 46 53.85
2.11 65 50 53.59
2.10 70 54 53.34
2.09 73 58 53.09
2.08 76 62 52.83
2.07 79 65 52.58
2.06 82 68 52.32
2.05 85 70 52.07
2.04 88 73 51.82
2.03 90 75 51.56
2.02 92 77 51.31
2.01 94 80 51.05
2.00 96 82 50.80
1.99 98 84 50.55
1.98 100* 85 50.29
1.97 102 86 50.04
1.96 104 88 49.78
1.95 106 90 49.53
1.94 107 91 49.28
1.93 108 93 49.02
1.92 110 94 48.77
1.91 112 96 48.51
1.90 113 97 48.26
1.89 115 98 48.01
1.88 117 100* 47.75
1.87 118 101 47.50
1.86 120 103 47.24
1.85 122 104 47.00
1.84 123 106 46.74


5501-19
WEAR CHART FOR VERTICAL BUSHING WEAR FOR

CASE LUBRICATED TRACK WITH 6.25 IN (158.7 mm) PITCH
B900595S

2.67 0 0 67.82
2.66 7 5 67.56
2.65 14 10 67.31
2.64 21 15 67.06
2.63 28 20 66.80
2.62 35 25 66.55
2.61 42 30 66.29
2.60 48 35 66.04
2.59 54 40 65.79
2.58 59 45 65.53
2.57 64 50 65.28
2.56 68 54 65.02
2.55 72 58 64.77
2.54 76 62 64.52
2.53 80 65 64.26
2.52 84 68 64.01
2.51 88 71 63.75
2.50 91 74 63.50
2.49 94 76 63.25
2.48 97 78 62.99
2.47 100* 80 62.74
2.46 103 82 62.48
2.45 106 84 62.23
2.44 109 86 61.98
2.43 112 88 61.72
2.42 115 90 61.47
2.41 118 92 61.21
2.40 121 94 60.96
2.39 96 60.71
2.38 98 60.45
2.37 100* 60.20
2.36 102 59.94


5501-20

FOR CASE LUBRICATED TRACK WITH 6.73 IN (171 mm) PITCH
89005958

2.81 0 0 71.37
2.80 5 4 71.12
2.79 10 8 70.87
2.78 15 12 70.61
2.77 20 15 70.34
2.76 25 19 70.10
2.75 30 23 69.85
2.74 35 27 69.60
2.73 40 31 69.34
2.72 45 35 69.09
2.71 50 39 68.83
2.70 55 42 68.58
2.69 60 46 68.33
2.68 65 50 68.07
2.67 70 54 67.82
2.66 73 58 67.56
2.65 76 62 67.31
2.64 79 65 67.06
2.63 82 68 66.80
2.62 85 70 66.55
2.61 88 73 66.29
2.60 90 75 66.04
2.59 92 77 65.79
2.58 94 80 65.53
2.57 96 82 65.28
2.56 98 84 65.02
2.55 100* 85 64.77
2.54 102 86 64.52
2.53 104 88 64.26
2.52 106 90 64.01
2.51 107 91 63.75
2.50 108 93 63.50
2.49 110 94 63.25
2.48 112 96 63.00
2.47 113 97 62.73
2.46 115 98 62.48
2.45 117 100* 62.23
2.44 118 101 61.98
2.43 120 103 61.72
2.42 122 104 61.47
2.41 123 106 61.21

5501-21
WEAR CHART FOR TRACK LINK WEAR FOR TRACK

WITH 6.25 IN (158.7 mm) PITCH
B900596J

3.79 0 96.27
3.77 7 95.76
3.75 14 95.25
3.73 20 94.74
3.71 26 94.23
3.69 32 93.73
3.67 38 93.22
3.65 44 92.71
3.63 50 92.20
3.61 56 91.69
3.59 62 91.19
3.57 67 90.68
3.55 72 90.17
3.53 77 89.66
3.51 82 89.15
3.49 87 88.65
3.47 92 88.14
3.45 96 87.63
3.43 100 87.12

5501-22
WEAR CHART FOR TRACK LINK WEAR WITH 6. 73 IN (171 mm) PITCH
89005965

3.78 0 96.01
3.76 7 95.50
3.74 14 95.00
3.72 20 94.49
3.70 26 93.98
3.68 32 93.47
3.66 38 92.96
3.64 44 92.46
3.62 50 91.95
3.60 56 91.44
3.58 62 90.93
3.56 67 90.42
3.54 72 89.92
3.52 77 89.41
3.50 82 88.90
3.48 87 88.39
3.46 92 87.88
3.44 96 87.38
3.42 100 86.87

5501-23
WEAR CHART FOR ONE BAR TRACK SHOE WEAR
89006118

2.06 0 52.32
2.02 4 51.31
1.98 8 50.29
1.93 12 49.02
1.89 16 48.01
1.85 20 46.99
1.81 24 45.97
1.76 28 44.70
1.72 32 43.69
1.68 36 42.67
1.64 40 41.66
1.59 44 40.39
1.55 48 39.37
1.51 52 38.35
1.47 56 37.34
1.42 60 36.07
1.38 64 35.05
1.34 68 34.04
1.30 72 33.02
1.25 76 31.75
1.21 80 30.73
1.17 84 29.72
1.13 88 28.70
1.08 92 27.43
1.04 96 26.42
1.00 100 25.40

5501-24
WEAR CHART FOR TWO BAR TRACK SHOE WEAR
B901623J

1.17 0 29.72
1.13 8 28.70
1.09 16 27.69
1.05 24 26.67
1.01 30 25.65
0.97 36 24.64
0.93 48 23.62
0.89 56 22.61
0.85 64 21.59
0.81 72 20.57
0.77 80 19.56
0.73 88 18.54
0.69 100 17.53
0.65 110 16.51
0.61 120 15.49
WEAR CHART FOR THREE BAR TRACK SHOE WEAR
B901624J

0.81 0 20.57
0.77 10 19.56
0.73 20 18.54
0.69 30 17.53
0.65 40 16.51
0.61 50 15.49
0.57 60 14.48
0.53 70 13.46
0.49 80 12.45
0.45 90 11.43
0.41 100 10.41
0.36 110 9.14
0.30 120 7.62

8-16600
8-16600

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1

DIVISION/SECTION SECTION NO. FORM NO.

Bur 8-16520 Issued 9-90 Printed in U.S.A

Safety Rules ........................... 1001-2 Torque Specifications . . . . . . . . . . . . . . . . . . 1001-5

Service Manual Introduction . . . . . . . . . . . . 1001-4

Bur 8-16530 Printed in U.S.A.

A This Symbol Shows Important Information About Safety In This Manual.

WARNING: If you wear clothing that is

WARNING: When doing checks and

A WARNING: Use msulated gloves or

CAUTION: Some components of this

A Support for swing cylinders

Welding will cause failure of the part and

SERVICE MANUAL INTRODUCTION

TORQUE SPECIFICATIONS - U.S. HARDWARE

Size Feet metres metres 7/16 in 70-84 95-114 9.7-11.6

7/8 in 400-480 542-651 55.3-66.4

1.0 in 580-696 787-944 80.2-96.2

1-1/8 in 800-880 1085-1193 111-122

1-1/4 in 1120-1240 1519-1681 155-171

1-3/8 in 1460-1680 1980-2278 202-232

1-1/2 in 1940-2200 2631-2983 268-304

TORQUE SPECIFICATIONS- STEEL HYDRAULIC FITTINGS

37 Degree Flare Fittings Straight Threads with 0-ring

Split Flange Mounting Bolts

5/16-18 15-20 20-27 2.1-2.8

3/8-16 20-25 26-33 2.8-3.5

7/16-14 34-45 47-61 4.7-6.2

1/2-13 55-65 74-88 7.6-9.0

5/8-11 140-150 190-203 19.4-20.7

Fluid and Lubricants Chart .................................................................... 1002-2

Maintenance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1002-3

8-42190 Printed in U.S.A.

FLUIDS AND LUBRICANTS CHART

Fuel tank 38 gallons 144 litres See Operators Manual

Crankcase 16 quarts 15.2 litres Multi-viscosity engine oil is specified

Reservoir for hydr~ulic 12 gallons 45 litres Case TCH Fluid

Transmission 8.5 gallons 32 litres Case TCH Fluid

Final drive (each) 7.5 quarts 7.1 litres Case FDL

Cooling system 5 gallons 19 litres A mixture of half ethylene glycol (anti-

Winch 9.5 quarts 9 litres Multipurpose gear. lubricant, API-GL-4

Batteries As required Add drinking water or distilled water.

Master cylinders As required Case TCH Fluid

Winch control As required DOT 3 brake fluid

Grease fittings As required Molydisulfide multipurpose grease

INTERVAL SERVICE INSTRUCTIONS

Do the After Delivery Check Operators Manual

After the first 100 Tighten all clamps on hoses at connecting

After 10 hours of Check level of engine oil Operators Manual

Check level of hydraulic oil. Operators Manual

Check level of coolant in coolant reservoir. Operators Manual

Drain water from primary fuel filter. Operators Manual

Lubricate pivot points for loader and blade. Operators Manual

After 100 hours of Check adjustment of parking brake. Section 7001

Check level of oil in winch and adapter. Seeton 9300

Check level of fluid in winch control. Section 9300

Lubricate universal joints and slip spline Operators Manual

INTERVAL SERVICE INSTRUCTIONS

Check level of gear lubricant in final Operators Manual